Filter media packs, methods of making and filter media presses

ABSTRACT

The disclosure is directed toward presses which may comprise planar or curved press plates that can be driven toward and away from each other such as via linear reciprocating movement to press filter media sheets as opposed to using rolls. The press plates can create such features as embossments that may have the ridges and grooves, brands, creases or other such features. The press can create pleated packs or individual panels for non-pleated packs. Additionally, a variety of embossed pleat packs, unique shapes, structural components and other pleat packs that may be formed by presses or other methodology are disclosed as well as filter cartridges using such pleat packs.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a continuation of U.S. Patent Application No.PCT/US2016/047283, filed Aug. 17, 2016; this patent application alsoclaims the benefit of U.S. Provisional Patent Application No.62/206,100, filed Aug. 17, 2015; and U.S. Provisional Patent ApplicationNo. 62/243,740, filed Oct. 20, 2015, the entire teachings and disclosureof which are incorporated herein by reference thereto.

FIELD OF THE INVENTION

This invention generally relates to filters, and more particularlyrelates to methods and machinery for forming features such asembossments (that may define grooves), creases, graphics, or otherfeatures into filter media packs and such filter media packs formedthereby.

BACKGROUND OF THE INVENTION

A variety of filter packs are known in the prior art, for example U.S.Pat. No. 6,780,217 to Palmer; U.S. Pat. No. 7,122,068 to Tate et al.;U.S. Pub. No. 2006/0151383 to Choi; U.S. Pat. No. 4,268,290 toBarrington. Each of the aforementioned patents and publicationsgenerally relate to pleated filter media elements.

There is also other filter media packs such as fluted media packsdescribed and shown for example in U.S. Pub. No. 2014/0260139 entitledRectangular Stacked Fluted Filter Cartridge to Merritt; and U.S. Pat.No. 7,318,851 entitled Filter Element to Brown et al.

Generally, the process for processing the filter media to be used insuch filter media packs employed by the above examples requires the useof rolls that have projecting features that rotate around a central axisin order to form embossments or other features into the filter mediapack such as shown for example in Choi, U.S. Pub. No. 2006/0151383entitled Pleated Corrugated Media and Method of Making. The advantage ofthe roll forming process is the ability for continuous processing inthat the rolls rotate and operate continuously on a continuous filtermedia sheet that is unwound from a filter media roll in a typicalprocess.

Various aspects of the present invention are directed towardsimprovements in the methods of making such features on media packs,improved media pack structures, and/or improved pleated embossed mediapacks as will be understood from the disclosure below.

BRIEF SUMMARY OF THE INVENTION

Some of the inventive aspects as defined by some of the independentclaims relate to pressing embossments, creases or other such filterfeatures into a filter media sheet with stamping dies that are in anon-rolled form.

For example, stamping dies may be reciprocated and preferably linearlyreciprocated back and forth by a hydraulic or electrically driven ram topress such features into the filter media sheet.

Various advantages and additional inventive features may flow from thispressing methodology. This methodology is particularly advantageous fora pleated filter media pack that is formed with grooves that can bedefined by (in other words formed by) embossments (e.g. the underside ofembossments and/or between embossments). Stated another way, the formedembossments in projecting as a raised structure from the typical planeof a filter media sheet may in preferred embodiments therefore take theform of grooves along the underside of the embossments and/or betweenembossments.

Additional and separate inventive aspects and independent claims aredirected toward inventive filter media packs. For example, in someembodiments of the invention, pleated filtering media packs may havediffering strength per filtering region; different shapes due to pleatdepth variation; stretched embossments as opposed to compressedembossments; a variety of new inventive shapes and/or nesting ofembossments; and/or new embossment patterns. All of these may be createdvia a press operation according to other inventive aspects.

Additional inventive aspects according to other independent claims arealso directed to other features such as the use of tabs that may beseparate structures or integrally formed in the media for purposes ofseal support and attachment; or tabs that may be in the form of clipsthat secure folds of individual pleats together to provide foradditional support.

In greater detail, some of the inventive features disclosed hereininclude the following in the paragraphs below, each of which may be usedindependently or in combination with another inventive aspect orfeature.

According to one inventive aspect, a method of forming a filter mediapack with a filter media sheet comprises: pressing at least one featureinto the filter media sheet repeatedly with stamping dies, the stampingdies being in a non-roll form; and assembling multiple pressed sectionsinto the filter media pack.

At least one pressed feature in the filter media sheet may be at leastone of score lines, embossments and graphics.

In a preferred embodiment, the stamping dies are successively pressedand released, during the pressing the stamping dies engaging for a dwelltime and then released.

In some embodiments, the dwell time for pressing may be between 0.2seconds and 300 seconds.

The dwell time may be at least 1 second in some embodiments.

In some embodiments, the assembling of multiple pressed sections intothe filter media pack can comprise gathering the multiple pressedsections by moving the pressed sections into overlaying relationship.The multiple pressed sections may be attached to each other by foldsand/or may be cut and otherwise separated and reassembled via a weldtool or seal bead attachment.

Although alternative packs are possible such as described in thebackground section above, preferred pleated embodiments are providedwhere the multiple pressed sections are attached that can avoid leakpaths or the need to seal. To provide, the method may further includecreasing the filter media sheet at spaced intervals to form a pluralityof pleat tips, the filter media sheet being a continuous sheet extendingthrough the pleat tips that is gathered subsequent to said creased toform a pleated filter media pack.

The method may yet further comprise conducting the creasing by the samestamping dies that perform other pressing. For example, the stampingdies can comprise mating female and male embossment features that formembossments and a crease feature comprising a male score extensioninteracting with a female score extension and forming the creasing.

The method may further comprise advancing the filter media sheet along atravel path, and extending the creasing in a direction that isperpendicular to the travel path and extending the embossments betweenadjacent creases.

According to a method of making dissimilar pleat panels, the methodfurther comprises advancing the filter media sheet along a travel path,extending the creasing in a direction that is perpendicular to thetravel path and pressing said embossments into a first panel of thefilter media sheet and skipping the pressing on a second panel that isconnected to the first panel by the creasing, such that the first andsecond panel mismatch, and successively repeating pressing of the firstand second panels.

This method may make the second panel that is flat and free ofembossments.

Alternatively, different embossments can be pressed into a filter mediasheet with downstream stamping dies, the downstream stamping dies beingin a non-roll form, the second embossments being different than saidembossments and being formed on the second panel.

The method may also comprise intermittently and successively advancingand stopping the filter media sheet along a travel path, wherein whilethe filter media sheet is stopped said pressing is conducted and whereinwhile the filter media sheet is advancing the filter media sheet passesfreely through the stamping dies.

Advantageous operations can optionally be performed during saidstopping. For example, the method can additionally conduct at least oneof the following operations downstream of the pressing dies: (a) bondingof adjacent pleats formed by a pleating operation; (b) trimming edges ofadjacent pleats, the edges extending in the direction of the travelpath; (c) cinching pleat tips at at least one of an inlet face and anoutlet face of the filter media pack to increase air flow entrances orexits at the at least one of the inlet face and outlet face; and (d)structurally coupling components to adjacent panels formed by saidpleating.

A more advanced methodology may also be practiced with multiple stampingdies while advancing the filter media sheet along a travel path. Themethod may also advance a plurality of sets of stamping dies along anendless path and over the filter media sheet along the travel path; andduring said pressing advance at least one of said sets of the stampingdies along the travel path at the same speed as the filter media sheetalong the travel path.

According to an embodiment, the stamping dies comprises a first die anda second die that together include a pair of plates movable toward andaway from each other. The plates including mating female and malefeatures that form the features for pressing. The method may furthercomprise linearly reciprocating the pair of plates toward and away fromeach other during said pressing with the mating female and male featuresreceived into each other with the filter media sheet therebetween.

According to an embodiment, each plate can comprise variable dimensionextending grooves and extending ribs to provides for mating female andmale embossment features, the variable dimension extending grooves andextending ribs extending having a varying dimension extending over at 6centimeters of length of the embossment with at least one width of atleast 2 millimeter, and at least one depth of at least 2 millimeter.

According to an embodiment the features comprise embossments pressedover a length of at least 6 centimeters of length of the embossment(preferably at least 10 centimeters for deeper packs) with at least onewidth of at least 2 millimeter, and at least one depth of at least 2millimeter.

While the presses are not progressive in many embodiments, certainadvantages can also be realized with a progressive stamping diearrangement, wherein two or more of the stamping dies engage the filtermedia sheet at different locations along the filter media sheet atdifferent times.

For example, when advancing the filter media sheet along a travel path,and with the progressive stamping die arrangement extending transverseto the travel path with dies extending in side by side relation, duringpressing the progressive stamping die arrangement can narrow a width ofthe filter media sheet extending transverse to the travel path atembossments formed by the pressing. This may be used to limit stretchingof the media and may gather the media towards the center of the traveldirection.

The method preferably comprises heating the media for the pressing to atemperature below a glass transition point of fibers of the media suchthat fibers are not bonded together due to said heating the media.

The heating preferably comprises elevating the temperature of the mediato between: 65 and 125 degrees Celsius for medias that comprise at least50% cellulose fibers by weight; and 65 and 205 degrees Celsius formedias that comprise at least 50% synthetic fibers by weight includingat least one of polypropylene, polyester or nylon fibers.

Such heating may further comprise pre-heating the filter media sheetbefore entering the stamping dies.

When heating is used, the method may further comprise active cooling ofthe filter media sheet after said pressing.

In an embodiment, the pressing forms embossments with a length ofgreater than 5 centimeters, and width of at least 2 millimeters and adepth of a least 2 millimeter, and further comprises stretching thefilter media sheet at said embossments to provide for an increase in airflow permeability in a pressed region of the filter media sheet.

In an embodiment, the pressing forms embossments having a depth ofbetween 2 millimeters and 8 millimeter, wherein the filter media packcomprises the pressed region of the filter media sheet with theremainder comprising a un-pressed region that is free of the pressing,the pressed region comprising between 20% and 80% of the filter mediapack, thereby creating different filter characteristic regions in thepleated filter media pack.

When the stretching feature is used, the filter media sheet can comprisea un-pressed air flow permeability prior to pressing with the pressedregion of the filter media sheet comprising a pressed air flowpermeability. Due to the stretching the pressed air flow permeabilitycan be at least 110% greater than the un-pressed air flow permeabilitymeasured by TAPPI T251 air flow permeability test.

For most filtration applications, the filter media sheet prior topressing has an air flow permeability of between 2 and 400 CFM (measuredby ASTM D737-04(2012) standard); and an initial gravimetric efficiencyof between 50% and 100% for ISO 12103-1, A2 Fine Test Dust measured byISO 5011 standard, and a caliper thickness of between 0.2 and 7millimeters.

In an curved plate embodiment, the stamping dies comprises a first dieand a second die that together include a pair of plates movable towardand away from each other, the plates including mating female and maleembossment features that form the embossments. The method furthercomprises linearly reciprocating the pair of plates toward and away fromeach other during said pressing with the mating female and maleembossment features received into each other with the filter media sheettherebetween, and wherein the pair of plates includes first plate havinga convex press surface that nests within a second plate having a concavepress surface.

In many of the preferred embodiments, the pressing operation formsembossments having a depth of between 2 millimeters and 8 millimetersand a width of between 2 and 16 millimeters, over a length of at least2.5 centimeters.

For many pressed media filtration applications, the filter media sheetcomprises at least 10% polymer fibers by weight and stretching thepolymer fibers during said pressing, wherein the polymer fibers compriseat least one of a fluorinated polymer, PVDF, polypropylene, polyesterand nylon, the media fibers include fibers having a diameter size ofless than 100 micron.

Another feature that can be used in conjunction with pressing iswelding. The feature can comprise folding a plurality of sections of thefilter media sheet into a pleated filter media pack with the sectionsextending adjacent each other between an inlet flow face and an outletflow face, and welding portions of adjacent sections together subsequentto the folding.

In many of the more preferred embodiments, the method further comprisesadvancing the filter media sheet along a travel direction and pressingpleat creases into the filter media sheet upstream and downstream fromthe at least one feature at upstream and downstream creases that extendtransversely relative to the travel direction and that form a pluralityof sections. For example, at least some of the sections can be embossedsections, with the at least one pressed feature including grooves thatextend in the embossed sections between upstream and downstream pleatcreases.

In grooved media, the filter media sheet can define a thickness betweena bottom surface and a top surface, with the grooves extending into thetop and bottom surfaces to define peaks and valley that defining aheight greater than a thickness of the filter media sheet. To facilitatebetter folding for pleating, pleat creases at an upstream end canlocated at a different elevation location than the pleat creases at adownstream end.

According to some embodiments that allow for adjustment of creasing, thepressing is conducted by a reciprocating ram that reciprocates a pair ofplate assemblies relative to each into and out of mating engagement withthe filter media sheet pressed therebetween, each plate assemblycomprising an emboss plate defining a plurality of male or female embossfeatures that engaging mate with male or female emboss features of theother plate assembly to press the grooves into the filter media sheet,each plate assembly further including upstream and downstream score barsadjustably mounted to opposed upstream and downstream of the embossplate, the score bars being adjustable to adjust the location of thepleat creases relative to the height of the grooves.

In some embodiments, the grooves comprise tapering grooves that widen ornarrow in a width that extends transverse to the travel direction as thegrooves extend between the upstream and downstream creases.

Different arrangements can be realized when not all embossments are thesame. For example, a first set of downstream grooves can start andextend from proximate the downstream crease toward the upstream creasebut terminate at least 15% short of the upstream crease, and a secondset of upstream grooves can start and extend from proximate the upstreamcrease toward the downstream crease but terminate at least 15% short ofthe downstream crease. With this arrangement the upstream and downstreamgrooves can be offset laterally but have overlapping portions such thatat any plane perpendicular to the travel direction the plane extendsthrough at least one of the upstream and downstream grooves to providecontinuous bridge strength through a middle region of the embossedsections.

Laminating can also optionally be conducted. A method may furthercomprise unwinding the filter media sheet from a first media roll andunwinding a laminate sheet from a second media roll, and advancing thefilter media sheet and the laminate sheet toward the pressing andsubsequently overlapping the filter media sheet and the laminate sheetprior to pressing, wherein the pressing forms the at least one featuresimultaneously into laminate sheet and the filter media sheet.

For some commercially practical pleated embodiments, the method canfurther comprise: unwinding the filter media sheet from a filter mediasheet roll; moving the filter media sheet through a press station havingfirst and second die assemblies to provide said pressing; reciprocatingfirst and second die assemblies toward and away from each other and intoand out of engagement with the filter media sheet to provide embossedsections of the filter media sheet and wherein the at least one featureto include grooves between peaks in the filter media sheet; and formingcreases and gathering the filter media sheet via folds at the creases toform a pleated filter media pack.

The pressing allows for other a variety of embossment options. Forexample, the filter media sheet has opposed side edges travellingparallel to the travel path, and the creases extend transverse to thetravel path and through the opposed side edges, and at least some of thegrooves can extend in a curved path.

In some curved embossments in pleated embodiments, the pleated filtermedia pack defines an inlet face along a first set of the crease and anoutlet face along a second set of the creases, wherein at least some ofthe grooves that extend in a curved path also extend from proximate atleast one of the inlet face or outlet face toward at least one of theopposed side edges.

At least some of the grooves can extend from proximate the inlet face toproximate the outlet face.

Some embodiments may also incorporate pocket pleats. The pleated filtermedia pack can comprise pleat panels that form pocket pleats whereinopposed side edges are joined together at select adjacent pleat panelsto form the pocket pleats. If curved embossments are used, the curvedpath of such embossments are arranged to direct fluid flow from at leastone of the inlet face and outlet face toward at least one of the opposedside edges to provide increased breathability.

Different shapes may also be realized and accomplished readily with suchpressing in some embodiments. For example, the method may move thefilter media sheet through a press station having first and second dieassemblies to provide said pressing wherein reciprocating first andsecond die assemblies toward and away from each other and into and outof engagement with the filter media sheet to provide embossed sectionsof the filter media sheet and wherein the at least one press featureincludes grooves between peaks in the filter media sheet. The method mayalso form creases and gather the filter media sheet via folds at thecreases to form a pleated filter media pack comprising a plurality ofpleat panels. To provide a different shape, a first set of pleat panelscan have a different span between the creases than a second set of pleatto provide the pleated filter media pack with a stepped inlet face and astepped outlet face.

Curved packs can also be accomplished. Such method can comprise movingthe filter media sheet along a travel path through a press stationhaving first and second die assemblies to provide said pressing whereinreciprocating first and second die assemblies toward and away from eachother and into and out of engagement with the filter media sheet toprovide embossed sections of the filter media sheet and wherein the atleast one feature to include grooves between peaks in the filter mediasheet; forming creases, wherein filter media sheet has opposed sideedges travelling parallel to the travel path, the creases extendtransverse to the travel path and through the opposed side edges,cutting a plurality of curves into at least one of the opposed sideedges; such that the pleated filter media pack defines a first flow facealong the creases and a second face non-parallel to the first flow facewith the curves extending and connecting therebetween; and gathering thefilter media sheet via folds at the creases and securing the adjacentpanels together at the second face to form a pleated filter media packcomprising a plurality of pleat panels.

When curved packs are cut, the curve cutting can cut curves into both ofthe opposed side edges of the filter media sheet and can displace theflow faces such that the first flow face can be displaced as may bedesired, which can be by at least 30 degrees relative to the secondface.

The method may form other curved shapes as well in other embodimentsthat can be accomplished without cutting. The method can move the filtermedia sheet through a press station having first and second dieassemblies to provide said pressing wherein reciprocating first andsecond die assemblies toward and away from each other and into and outof engagement with the filter media sheet to provide embossed sectionsof the filter media sheet and wherein the at least one feature toinclude grooves between peaks in the filter media sheet; and formcreases and gather the filter media sheet via folds at the creases toform a pleated filter media pack comprising a plurality of pleat panels;and displace pleat panels from adjacent pleat panels to provide aportion with a curved shape or a corkscrew shape to the pleated filtermedia pack, wherein the curved shape or corkscrew shape is formedwithout cutting.

The method affords the opportunity to use additional structures such astabs. The method may also secure tabs to at least some of the pleatpanels, the tabs being formed of a material more rigid than the filtermedia sheet.

In one embodiment, the tabs serve a pleat securement function comprisingsecuring two adjacent pleat panels together with each of the tabs, eachtab having a first portion secured a first of the adjacent pleat panelsand another portion secured to a second of the adjacent pleat panels.

In another embodiment, the tabs project outward from an end face or aside face of the pleated filter media pack, and wherein an elastomericseal adapted for forming a seal with a housing is provided with the tabsembedded in the elastomeric seal and supporting the seal.

Integral tabs in the filter media sheet can also be pressed or cut. Forexample, the method can form integral tabs into the filter media sheetthat extend outward from at least some of the pleat panels; and usethose to secure a seal by embedding the tabs within the seal.

According to more specific inventive aspect directed at embossed pleatedfilter media packs, a method of forming a pleated filter media pack witha filter media sheet, comprises: pressing embossments into the filtermedia sheet repeatedly with stamping dies, the stamping dies being in anon-roll form; pleating the filter media sheet; and gathering thepleated filter media sheet to provide the pleated filter media pack.

The filter media sheet can be creased at spaced intervals to form aplurality of pleat tips, the embossments disposed at least partiallybetween pleat tips.

Preferably, the creasing is conducted the creasing by said stampingdies, the stamping dies comprising mating female and male embossmentfeatures that form the embossments and a crease feature comprising amale score extension interacting with a female score extension andforming the creasing.

In some embodiments, the creased intervals are uniformly spaced andwherein the pleats extend between pleat tips at an inlet face and pleattips at an outlet face, and the distance between the pleat tips at theinlet face and the pleat tips at the outlet face remain constant.

In other embodiments, at least some of the intervals are non-uniformlyspaced and wherein the pleats extend between pleat tips at an inlet faceand pleat tips at an outlet face, the distance between the pleat tips atthe inlet face and the pleat tips at the outlet face varying andcreating the pleated filter media pack that is irregularly shaped with aregion of the inlet face and the outlet face extending obliquely.

Preferably, the creasing comprises scoring the filter media sheet.

In many on the more preferred embodiments, the method further comprisesadvancing the filter media sheet along a travel path, extending thecreasing in a direction that is perpendicular to the travel path andextending the embossments between adjacent creases.

Further, the method may advance the filter media sheet along a travelpath, extend the creasing in a direction that is perpendicular to thetravel path and press said embossments into a first panel of the filtermedia sheet and skip the pressing on a second panel that is connected tothe first panel by the creasing, such that the first and second panelmismatch, and successively repeating pressing of the first and secondpanels.

This can result in an arrangement wherein the second panel is flat andfree of embossments.

The method may comprise use of multiple die sets. The method may pressdifferent embossments into a filter media sheet with downstream stampingdies, the downstream stamping dies being in a non-roll form, the secondembossments being different than said embossments and being formed onthe second panel.

When used, the crease feature can comprises an upstream crease featureand a downstream crease feature formed on the stamping dies, theembossment features extending between the upstream crease feature andthe downstream crease feature, wherein during pressing, upstream anddownstream creases are formed by the stamping dies.

While continuous media advancement can be done with a loop of dies orindexable dies, the pressing methodology allows for and mayadvantageously use an intermittent process that comprises intermittentlyand successively advancing and stopping the filter media sheet along atravel path, wherein while the filter media sheet is stopped saidpressing is conducted and wherein while the filter media sheet isadvancing the filter media sheet passes freely through the stampingdies.

For example, during intermittent stoppage, the method additionallyconduct at least one of the following operations downstream of thepressing dies: (a) bonding of adjacent pleats formed by said pleating;(b) trimming edges of adjacent pleats, the edges extending in thedirection of the travel path; (c) cinching pleat tips at at least one ofan inlet face and an outlet face of the pleated filter media pack toincrease air flow entrances or exits at the at least one of the inletface and outlet face; and (d) structurally coupling components toadjacent panels formed by said pleating.

The method can further comprise an optional continuous operation of:advancing the filter media sheet along a travel path; advancing aplurality of sets of stamping dies along an endless path and over thefilter media sheet along the travel path; and during said pressingadvancing at least one of said sets of the stamping dies along thetravel path at the same speed as the filter media sheet along the travelpath.

The stamping dies can comprise a first die and a second die thattogether include a pair of plates movable toward and away from eachother, the plates including mating female and male embossment featuresthat form the embossments. The method may then further comprise linearlyreciprocating the pair of plates toward and away from each other duringsaid pressing with the mating female and male embossment featuresreceived into each other with the filter media sheet therebetween.

In some preferred embodiments and while alternatives are possible, theplates extend in parallel planes and each plate comprises linearlyextending grooves and linearly extending ribs to provides for the matingfemale and male embossment features, the linearly extending grooves andlinearly extending ribs maintaining a consistent depth and height for atleast 90% of the length of central portions of the embossments extendingbetween pleat tips that is formed during said pressing and pleating.

The method may further comprise pressing tapered end portions intoopposed ends of the central portions of the embossments adjacent thepleat tips, the tapered end portions extending toward the pleat tips.

In some alternative embodiments, each plate can comprise variabledimension extending grooves and extending ribs to provides for themating female and male embossment features, the variable dimensionextending grooves and extending ribs extending having a varyingdimension extending over at 6 centimeters of length of the embossmentwith at least one width of at least 2 millimeter, and at least one depthof at least 2 millimeter.

According to a feature and advantage with some embodiments, theembossments form a pattern that is incapable of duplication by rolls.Pressing utilizing plates opens up options previously not available.

For deeper packs, preferably the method presses each embossment over alength of at least 10 centimeters.

While non-progressive stamping can be done as according to many of theembodiments, the stamping dies can also comprise a progressive stampingdie arrangement, wherein two or more of the stamping dies engage thefilter media sheet at different locations along the filter media sheetat different times.

In progressive stamping, the method can advance the filter media sheetalong a travel path, and wherein the progressive stamping diearrangement extends transverse to the travel path with dies extending inside by side relation, and wherein during pressing the progressivestamping die arrangement narrows a width of the filter media sheetextending transverse to the travel path at the embossment.

In many of the embodiments, the pleating creates pleats having a pleatdepth of greater than 6 centimeters, and said pressing forms embossmentswith a length of greater than 5 centimeters, and width of at least 2millimeters and a depth of a least 2 millimeter.

Preferably, the embossments extend at least 90% of the span of the pleatdepth.

To better set the pressed embossments, the method can further compriseheating the media for the pressing to a temperature below a glasstransition point of fibers of the media such that fibers are not bondedtogether due to said heating the media.

The heating can comprise elevating the temperature of the media tobetween: 65 and 125 degrees Celsius for medias that comprise at least50% cellulose fibers by weight; 65 and 205 degrees Celsius for mediasthat comprise at least 50% synthetic fibers by weight including at leastone of polypropylene, polyester or nylon fibers.

Heating may also comprise pre-heating the filter media sheet beforeentering the stamping dies and/or active cooling of the filter mediasheet after said pressing.

With a press, an advantageous dwell time to set pressed embossments canbe done comprising engaging the filter media sheet with the stampingdies during each pressing for a dwell time of between 0.2 and 300seconds.

The pleated filter media pack can comprise upstream pleat tips at anupstream face and downstream pleat tips at a downstream face with pleatpanels extending between upstream pleat tips and downstream pleat tips,the pleat tips extending transversely between opposed side edges, withthe method further comprising sealing side edges and bonding adjacentpleat panels together at locations between side edges in someembodiments.

According to some embodiments, said bonding comprises welding the filtermedia sheet to itself at various locations between opposed side edges.

Such welding can conducted on at least one of the upstream pleat tipsand the downstream pleat tips at a plurality of spaced locations alongeach of said at least one of the upstream pleat tips and the downstreampleat tips.

Such welding can be conducted in an array between adjacent panels at aplurality of spaced locations extending transversely between opposedside edges and at a plurality of spaced locations extending transverselybetween upstream pleat tips and downstream pleat tips.

Such bonding can alternatively comprise adhesively attaching theembossments a first panel to an adjacent second panel.

The pleated filter media pack can comprise upstream pleat tips at anupstream face and downstream pleat tips at a downstream face with pleatpanels extending between upstream pleat tips and downstream pleat tips,the pleat tips extending transversely between opposed side edges, withthe method further comprising welding opposed side edges of alternatingadjacent pleat panels together to form pocket pleats in someembodiments.

The pressing can optionally provide a further advantage of stretchingthe filter media sheet at the embossments to provide for an increase inair flow permeability in a pressed region of the filter media sheet.

Stretching may appreciably affect filtration parameters. For example,the filter media sheet comprises a un-pressed air flow permeabilityprior to pressing and the pressed region of the filter media sheetcomprises a pressed air flow permeability, wherein due to the stretchingthe pressed air flow permeability being at least 110% greater than theun-pressed air flow permeability measured by TAPPI T251 air flowpermeability test.

In some embodiments, the pressed air flow permeability is between 125%and 500% greater the un-pressed air flow permeability.

This may be used to create different filtering regions. The pleatedfilter media pack can comprise the pressed region of the filter mediasheet with the remainder comprising a un-pressed region that is free ofthe pressing, the pressed region comprising between 20% and 80% of thepleated filter media pack, thereby creating different filtercharacteristic regions in the pleated filter media pack.

In some embodiments, at least one efficiency layer is arranged along anupstream inlet face of the pleated filter media pack relative to apredetermined direction of airflow while configuring the filter for usein a reverse pulsing application; or alternatively the support layer isarranged along an upstream inlet face of the pleated filter media packrelative to a predetermined direction of airflow while configuring thefilter for use in a single use disposable filter application.

The method is particularly useful in deep pleat packs and may extend thepleats between pleat tips at an inlet face and pleat tips at an outletface with a rectangular periphery extending between the inlet face andthe outlet face, and extending a sealing system around the rectangularperiphery, and wherein said pleating creates pleats having a pleat depthof greater than 6 centimeters, and preferably a pleat depth of at least15 centimeters, and much deeper if desired.

For most filtration applications, the filter media sheet prior topressing has an air flow permeability of between 10 and 150 CFM(measured by ASTM D737-04(2012) standard); and an initial gravimetricefficiency of between 50% and 100% for ISO 12103-1, A2 Fine Test Dust(measured by ISO 5011 standard), and a caliper thickness of between 0.2and 1 millimeters.

The pressing can also create graphics. The method may further compriseforming at least some of the embossments on an external visible surfaceof the pleated filter media pack in the form of a brand that provides atleast one of brand identification, flow direction, installationinformation, filter media parameters, and part number.

Different types of embossments may be used. The method may furthercomprise forming a second set of embossments of a different form thatare separate from said at least some of the embossments on an externalvisible surface.

According to a curved die arrangement, the stamping dies comprises afirst die and a second die that together include a pair of platesmovable toward and away from each other, the plates including matingfemale and male embossment features that form the embossments, furthercomprising linearly reciprocating the pair of plates toward and awayfrom each other during said pressing with the mating female and maleembossment features received into each other with the filter media sheettherebetween, and wherein the pair of plates includes first plate havinga convex press surface that nests within a second plate having a concavepress surface.

Preferably, such pressing forms embossments having a depth of between 2millimeters and 8 millimeters and a width of between 2 and 16millimeters.

For better pressing, the filter media sheet comprises at least 10%polymer fibers by weight (more preferably at least 20%) and can involvestretching the polymer fibers during said pressing.

Such polymer fibers comprise at least one of a fluorinated polymer,PVDF, polypropylene, polyester and nylon, as commonly used in filtrationor other such polymers.

The pressed filter media sheet can comprise at least one of thefollowing media fibers: wet laid micro-fiberglass, nylon, polypropylene,polyester, wet laid cellulose and wet laid polymer, the media fibersinclude fibers having a diameter size of less than 100 micron.

According to another inventive aspect that can employ an assembly linemachine, a method of forming a filter media pack with a filter mediasheet, comprises: unwinding the filter media sheet from a filter mediasheet roll; moving along a travel path the filter media sheet through apress station comprising a cooperating pair of first and second stampingdies; pressing at least one feature into panels of a the filter mediasheet with the pair of stamping dies; reciprocating the first and secondstamping dies toward and away from each other during said pressing; andassembling multiple pressed sections into the filter media pack.

Preferably, said reciprocating comprises linear reciprocating movement.

According to many embodiments, the method reciprocates first and seconddie assemblies toward and away from each other and into and out ofengagement with the filter media sheet provides embossed sections of thefilter media sheet and wherein the at least one feature to includegrooves between peaks in the filter media sheet; and forms creases andgathering the filter media sheet via folds at the creases to form apleated filter media pack comprising a plurality of pleat panels.

In many of the preferred embodiments, the at least one press featurecomprises embossments, wherein the stamping dies are successivelypressed and released, during the pressing the stamping dies engaging fora dwell time and then released.

Such dwell time can be between 0.2 seconds and 300 seconds to holdembossment shape.

The method can further involve heating the filter media sheet for thepressing to a temperature below a glass transition point of fibers ofthe media such that fibers are not bonded together due to said heatingthe filter media sheet.

Such heating can comprise heating at least one of the first and seconddies to a temperature above 65 degrees Celsius to heat press the filtermedia sheet during the dwell time.

Such heating can also comprise pre-heating the filter media sheet toabove ambient.

Such heating may elevate the temperature of the media to between: 65 and125 degrees Celsius for medias that comprise at least 50% cellulosefibers by weight; or 65 and 205 degrees Celsius for medias that compriseat least 50% synthetic fibers by weight including at least one ofpolypropylene, polyester or nylon fibers comprising active cooling ofthe filter media sheet after said pressing.

Such method may also comprise active cooling of the filter media sheetafter said pressing.

The method can further comprise folding the filter media sheet havingembossments after the heat pressing to create pleat panels and pleatshaving a pleat depth of greater than 6 centimeters, and said pressingforms embossments with a length of greater than 5 centimeters, and widthof at least 2 millimeters and a depth of a least 2 millimeter.

In some embodiments, the pleats comprise first pleat panels havingembossments and second pleat panels free of embossments.

The method can further comprise after said heat pressing: bonding ofadjacent pleats formed by a pleating operation.

The method can also comprise after said heat pressing: trimming edges ofadjacent pleats, the edges extending in the direction of the travelpath.

The method can also comprise after said heat pressing: cinching pleattips at at least one of an inlet face and an outlet face of the filtermedia pack to increase air flow entrances or exits at the at least oneof the inlet face and outlet face.

The method can further comprise pressing the at least one feature to bea plurality of embossments over a length of at least 10 centimeters, andpreferably over a length of at least 20 centimeters.

According to another inventive aspect, a method of forming a filtermedia pack with a filter media sheet, comprises: pressing embossmentsinto the filter media sheet; and stretching the filter media sheet atthe embossments through said pressing to provide the filter media sheetwith decreased initial filtration efficiency, an increased porosity andan increased air flow permeability relative to the filter media sheetprior to pressing.

Such pressing can form stretched embossments having a length of at least5 centimeters, a depth of between 2 millimeters and 8 millimeter, and awidth of between 2 millimeters and 16 millimeters.

The filter media pack can comprise the pressed region of the filtermedia sheet with the remainder comprising a un-pressed region that isfree of the pressing, the pressed region comprising between 20% and 80%of the filter media pack, thereby creating different filtercharacteristic regions in the pleated filter media pack

In some embodiments, the filter media sheet comprises a un-pressed airflow permeability prior to pressing and the pressed region of the filtermedia sheet comprises a pressed air flow permeability, wherein due tothe stretching the pressed air flow permeability being at least 110%greater than the un-pressed air flow permeability measured by TAPPI T251air flow permeability test.

The filter media sheet prior to pressing can have an air flowpermeability of between 2 and 400 CFM (measured by ASTM D737-04(2012)standard); and an initial gravimetric efficiency of between 50% and 100%for ISO 12103-1, A2 Fine Test Dust measured by ISO 5011 standard, and acaliper thickness of between 0.2 and 7 millimeters.

To facilitate pressing, said pressing can comprise linearlyreciprocating stamping dies comprises a first die and a second die thattogether include a pair of plates movable toward and away from eachother, the plates including mating female and male embossment featuresthat form the embossments, during linearly reciprocating the matingfemale and male embossment features are received into each other withthe filter media sheet pressed therebetween.

Such press plates can extend in parallel planes and each plate compriseslinearly extending grooves and linearly extending ribs to provides forthe mating female and male embossment features, the linearly extendinggrooves and linearly extending ribs maintaining a consistent depth andheight for at least 90% of the length of central portions of theembossments extending between pleat tips that is formed during saidpressing and pleating.

In a preferred operation, the stamping dies are successively pressed andreleased, during the pressing the stamping dies engaging for a dwelltime and then released, wherein the dwell time is at least 0.2 seconds.

Also preferably, the filter media sheet is heated for the pressing to atemperature below a glass transition point of fibers of the media suchthat fibers are not bonded together due to said heating the filter mediasheet.

Such heating can comprise heating at least one of the first and seconddies to a temperature above 65 degrees Celsius to heat press the filtermedia sheet during the dwell time.

Another inventive aspect is directed toward an apparatus for processinga filter media sheet that is unwound from a filter media roll, and thatmay be used to perform any of the methods above or herein. The apparatuscomprises: a media unwind region adapted for receiving the filter mediaroll; a press comprising a pair of cooperating stamping dies disposeddownstream from the media unwind region, the press including a ramdriving the stamping dies into and out of engagement, the stamping diescomprising mating female and male embossment features that are adaptedto form embossments in the filter media sheet; and a media conveyingmechanism arranged for advancing the filter media sheet through thepress along a travel path.

The ram can comprise an electric or fluid powered linear actuator incommunication with a control that is configured to successively drivethe ram to reciprocate the stamping dies into and out of engagement.

Such a control can be configured to press the stamping dies inengagement for a dwell time of at least 0.2 seconds.

The apparatus may optionally include a heater acting upon the stampingdies and having an operative condition that heats the stamping dies toat least 65 degrees Celsius.

Such control can also be in communication with the media conveyingmechanism, with the control configured to stop the conveying mechanismwhen the stamping dies are engaged and drive the conveying mechanismwhen the stamping dies are disengaged.

In the apparatus, the female embossment features can comprise grooveshaving a length of at least 5 centimeters, a depth of between 2millimeters and 8 millimeter, and a width of between 2 millimeters and16 millimeters.

Preferably, in an engaged position, a gap between the stamping dies isprovided that measures no less than 50% of a thickness of the filtermedia sheet.

The stamping dies comprise a pair of plate assemblies, the pair of plateassemblies moving into and out of mating engagement for pressing thefilter media sheet therebetween, each plate assembly comprising anemboss plate defining the male or female emboss features that engagingmate with male or female emboss features of the other plate assembly,each plate assembly further including upstream or downstream score barsadjustably mounted to opposed upstream and downstream of the embossplate, the score bars being adjustable to adjust the location and havinga pleat score line for forming pleat creases in the filter media sheet.

For pleated packs, the apparatus may include a pleater downstream of thepress configured to fold the filter media sheet along the creases.

Optionally, the apparatus includes a trimmer arranged on one or bothsides of the travel path, the trimmer being arranged upstream ordownstream from the press and adapted to trim one or both of opposedside edges of the filter media sheet.

Optionally, the apparatus comprises an adhesive applicator arranged toapply adhesive above or below the filter media sheet along the travelpath.

Optionally, the apparatus comprises a plunge welder and an anvildownstream from the press, the plunge welder arranged along the travelpath and movable toward and away from an anvil, the plunge welder andanvil having weld contact features adapted to form at least one ofpocket welds, stitches, cinches, or sealed seams into the filter mediasheet.

Optionally, the apparatus further comprises a cutter cutting transverserelative to the travel path for cutting through the media to spans thatdefine media packs.

In some embodiments of the apparatus, the stamping dies comprise a pairof plate assemblies, the pair of plate assemblies moving into and out ofmating engagement for pressing the filter media sheet therebetween, eachplate assembly comprising an emboss plate defining the male or femaleemboss features that engaging mate with male or female emboss featuresof the other plate assembly, each plate assembly including upstream anddownstream score bars mounted to upstream and downstream ends of theemboss plate.

Optionally, the pair of stamping dies can comprise a progressivestamping die arrangement.

The press may comprise a plurality of stamping dies are providedmoveable along an endless path with a portion of the endless path alongthe travel path with a speed matched to that of the media conveyingmechanism. The path may be a loop or linear indexing as shown inembodiments herein.

In alternative embodiment of the apparatus, the stamping dies may have aplanar extending section including the mating female and male embossmentfeatures for forming embossments, and lobed regions on one or both endsfor creating creases for forming pleats in the filter media sheets, thedie being rotatable in addition to being driven in reciprocatingmovement.

The embossment features may further comprise mating taper regions formedinto the stamping dies at upstream and downstream ends of the grooves.

Such mating tapering regions can extend from bottoms of grooves towardridges formed on either of each groove.

In such an apparatus, the embossment features can advantageously extendat least 90% full span of the emboss plate between upstream anddownstream score bars.

Another inventive aspect is directed toward a pleated filter media pack,comprising: a filter media sheet that includes a plurality of folds thatform a plurality of pleat panels extending between first pleat tipsalong a first face of the filter media and second pleat tips along asecond face of the filter media, the pleat tips and the pleat panelsextending between opposed side edges of the pleated filter media pack,the plurality of pleat panels including first pleat panels and secondpleat panels; and wherein the first pleat panels of are formed with adifferent strength or filtering characteristic defined by the filermedia sheet than the second pleat panels.

In the pleated filter media pack, the first pleat panels may comprisefirst embossments formed therein that are not formed on the second pleatpanels.

For example, the second pleat panels can flat or may have otherfeatures.

In the pleated filter media pack, the first embossments can comprisegrooves extending at least 90% of a distance between first pleat tipsand second pleat tips.

In the pleated filter media pack, the first pleat panels can be pressedto include stretched regions and wherein the second pleat panels areunpressed.

In the pleated filter media pack, the pleat panels can extend at least 5centimeters between creases, and wherein the embossments can have alength of at least 5 centimeters, a depth of between 2 millimeters and 8millimeter, and a width of between 2 millimeters and 16 millimeters, andwherein at least 3 pleat panels per centimeter across the first face orsecond face of the filter media can be provided.

Preferably, the pleat panels extend at least 10 centimeters betweencreases and the embossments extend a length at least 10 centimeters.

The filter media pack can comprise a pressed region of the filter mediasheet with the remainder comprising a un-pressed region that is free ofthe pressed region, the pressed region comprising between 20% and 80% ofthe filter media pack, thereby creating different filter characteristicregions in the pleated filter media pack

Such unpressed region can comprise an un-pressed air flow permeabilityand the pressed region of the filter media sheet can comprise a pressedair flow permeability, wherein due to the stretching the pressed airflow permeability being at least 110% greater than the un-pressed airflow permeability measured by TAPPI T251 air flow permeability test.

For most applications, in the pleated filter media pack, the filtermedia sheet prior to pressing (e.g. any unpressed region) has an airflow permeability of between 2 and 400 CFM (measured by ASTMD737-04(2012) standard); and an initial gravimetric efficiency ofbetween 50% and 100% for ISO 12103-1, A2 Fine Test Dust measured by ISO5011 standard, and a caliper thickness of between 0.2 and 7 millimeters.

According to another inventive aspect, some embodiments are non-cuboid.For example, the filter media sheet can include a plurality of foldsthat form a plurality of pleat panels extending between first pleat tipsalong an inlet face of the filter media and second pleat tips along anoutlet face of the filter media, the pleat tips and the pleat panelsextending between opposed side edges of the pleated filter media pack.The plurality of pleat panels can include first pleat panels and secondpleat panels; and wherein the first pleat panels extend at a differentdepth than second pleat panels as between the first pleat tips and thesecond pleat tips to form a pleated filter media pack configuration thatis other than a rectangular cuboid.

Such folds can be formed at creases, with a first set of pleat panelshaving a different span between the creases than a second set of pleatto provide the pleated filter media pack with at least one of a steppedinlet face and a stepped outlet face.

Such a pleated filter media pack can have both of a stepped inlet faceand a stepped outlet face in certain embodiments shown herein.

In the pleated filter media pack, the first pleat panels can comprisefirst embossments formed therein, wherein the pleat panels extend atleast 5 centimeters between creases, and wherein the embossments havinga length of at least 5 centimeters, a depth of between 2 millimeters and8 millimeter, and a width of between 2 millimeters and 16 millimeters,and wherein at least 3 pleat panels per centimeter across the first faceor second face of the filter media are provided.

Preferably, the pleat panels extend at least 10 centimeters betweencreases and the embossments extend a length at least 10 centimeters.

In the pleated filter media pack, the filter media pack can comprises apressed region of the filter media sheet with the remainder comprising aun-pressed region that is free of the pressed region, the pressed regioncomprising between 20% and 80% of the filter media pack, therebycreating different filter characteristic regions in the pleated filtermedia pack. The filter media sheet prior to pressing (e.g. unpressedregions) can have an air flow permeability of between 2 and 400 CFM(measured by ASTM D737-04(2012) standard); and an initial gravimetricefficiency of between 50% and 100% for ISO 12103-1, A2 Fine Test Dustmeasured by ISO 5011 standard, and a caliper thickness of between 0.2and 7 millimeters.

In some preferred embodiments, the second pleat panels are flat.

In some preferred embodiments of the pleated filter media pack, thefirst embossments comprise grooves extending at least 90% of a distancebetween first pleat tips and second pleat tips.

In some embodiments, one of the inlet and outlet faces extendsperpendicularly to a surrounding outer rectangular periphery, whereinonly one of the inlet and outlet faces is stepped.

In some embodiments, sets of the panels progressively get longer orshorter as the panels extend from one side to another side of thepleated filter media pack, wherein at least 3 distinct panel spans areprovided, not including end panels.

According to another inventive aspect, a filter media pack, comprises: afilter media sheet that includes a plurality of embossments that arestretched and formed into the filter media sheet wherein the filtermedia sheet has a free area free of the embossments and an embossedarea, the embossed area having a decreased initial filtrationefficiency, an increased porosity and an increased air flow permeabilityrelative to the free area.

In such a filter media pack, filter media pack includes first panelscomprising first embossments formed therein that are not formed onsecond panels.

Preferably, the second panels are flat and overlay in contact the firstpanels.

More preferably, the first and second panels are connected at folds andform a pleated filter media pack.

The embossments can comprise grooves extending at least 90% of adistance ends of the first panels.

The embossed area can be pressed to include stretched regions andwherein the free area is unpressed.

Typically in such stretched embossments in a filter media pack, theembossments extend a length at least 5 centimeters, and wherein theembossments having a length of at least 5 centimeters, a depth ofbetween 2 millimeters and 8 millimeter, and a width of between 2millimeters and 16 millimeters, and wherein the free area has an airflow permeability of between 2 and 400 CFM (measured by ASTMD737-04(2012) standard); and an initial gravimetric efficiency ofbetween 50% and 100% for ISO 12103-1, A2 Fine Test Dust measured by ISO5011 standard, and a caliper thickness of between 0.2 and 7 millimeters.

Another inventive aspect is directed toward a filter media pack,comprising: a plurality of filter media panels formed from a filtermedia, the plurality of filter media panels in overlaying relation toprovide the filter media pack and extending between an outlet face andan inlet face, with a flow path running through the filter media fromthe inlet face to the outlet face; a plurality of tabs directly andseparately connected to at least some of the panels, the tabs extendingoutwardly from a side or the inlet or outlet face of the filter mediapack; and a seal of elastomeric material having a continuous annularsealing surface, the tabs being embedded in the seal.

The seal material may additionally be embedded within a peripheralportion of the filter media of the filter media pack.

The tabs may comprise integrally formed tabs of the filter mediaextending from an edge of the filter media panels.

Alternatively, the tabs are formed of a material more rigid than thefilter media sheet.

When non-integral tabs are used, the tabs may have a first portionoverlaying and bonded to the filter media, and a second portion havingapertures, the seal material extending through the apertures.

The elastomeric material of the seal is typically molded to the tabs,and the elastomeric material is preferably molded in surroundingrelation of the media pack, but may be offset from a flow face as well

Another inventive aspect of the present invention is directed towardfilter media pack, comprising: a plurality of filter media panels formedfrom a filter media, the plurality of filter media panels in overlayingrelation to provide the filter media pack and extending between anoutlet face and an inlet face, with a flow path running through thefilter media from the inlet face to the outlet face; a plurality of tabsdirectly and separately connected to at least some of the panels, eachtab securing at least two of the panels together.

Preferably, the tabs are formed of a material more rigid than the filtermedia sheet.

Each tab can have a hinge and wings extending from the hinge. The filtermedia pack may further comprise a fastener securing the wings together.

When employed on a pleated filter media pack, the panels and filtermedia comprises a filter media sheet that includes a plurality of foldsthat form a plurality of pleat panels extending between first pleat tipsalong an inlet face of the filter media and second pleat tips along anoutlet face of the filter media, the pleat tips and the pleat panelsextending between opposed side edges of the pleated filter media pack,the plurality of pleat panels including first pleat panels and secondpleat panels; and the tabs pinch and securing pleats together.

Such tabs can be advantageously used with embossments on at least someof the pleat panels that extend between the inlet face and the outletface, with the tabs being in overlapping relation with creases formingthe folds at at least one of the inlet and outlet faces and inoverlapping relation with the embossments.

The first pleat panels can comprise first embossments formed thereinthat are not formed on the second pleat panels, and/or the embossmentscan comprise grooves extending at least 90% of a distance between firstpleat tips and second pleat tips.

Another inventive aspect of the present invention is directed toward apleated filter media pack, comprising: a filter media sheet thatincludes a plurality of folds that form a plurality of pleat panelsextending between first pleat tips along a first face of the filtermedia and second pleat tips along a second face of the filter media, thepleat tips and the pleat panels extending between opposed side edges ofthe pleated filter media pack, the plurality of pleat panels includingfirst pleat panels and second pleat panels, wherein the filter mediapack includes four sides in surrounding relation and that extend fromthe inlet face to the outlet face; and wherein adjacent sets of pleatpanels are shifted relative to each other such that at least two of thesides are non-planar.

In such a pleated filter media pack, two of the sides may be planar andtwo of the sides may be curved.

Alternatively, all four of the sides are non-planar and curved, theadjacent sets of panels being rotated relative to each other about anaxis that is perpendicular to the pleat panels.

Another inventive aspect of the present invention is directed toward apleated filter media pack, comprising: a filter media sheet thatincludes a plurality of folds that form a plurality of pleat panelsextending between a first end face of the filter media and a second endface of the filter media, the folds extending between opposed side edgesof the pleated filter media pack, the plurality of pleat panelsincluding first pleat panels and second pleat panels, and wherein thefilter media pack includes four sides in surrounding relation and thatextend from the first end face to the second end face; and furthercomprising embossments in the form of grooves on at least some of thepleat panels extending in a curved path along the length of the groovesas the grooves extend between the first end face and the second endface, the grooves making a turn of at least 20 degrees.

The aspect may additionally comprise straight grooves that have a straitportion along the length of the straight grooves.

This feature may be used with curved packs, where the first and secondend faces may planar, and wherein at least two of the sides are planarand at least one of the sides is curved, and preferably both sides arecurved.

Preferably, the curvature of the at least one side matches the curvatureof the curved path of the embossments.

This curvature may be also advantageously used with pocket pleats,wherein the pleated filter media pack comprises pleat panels that formpocket pleats wherein opposed side edges are joined together at selectadjacent pleat panels to form the pocket pleats, the curved patharranged to direct fluid flow from at least one of an inlet face and anoutlet face formed by one of the end faces toward at least one of theopposed side edges.

Another inventive aspect of the present invention is directed toward afilter media pack, comprising: a plurality of filter media panels formedfrom a filter media including first panels and second panels, theplurality of filter media panels in overlaying relation to provide thefilter media pack and extending between an outlet face and an inletface, with a flow path running through the filter media from the inletface to the outlet face; a plurality of first embossments on the firstpanels, and a plurality of second embossments on the second panels, thefirst embossments and the second embossments and nesting either withinor adjacent each other.

In such a nested arrangement the first embossments can extend into aregion between the first and second panels, and second embossments canextend in the region between first and second media panels.

Such nested embossments can nest within each other and/or theembossments can be offset and adjacent each other.

The nesting arrangement can provide compactness. The first panel and thesecond panel can closer together than a maximum depth of the firstembossment and a maximum depth of the second embossment, combined.

Another inventive aspect of the present invention is directed toward afilter media pack, comprising: a plurality of filter media panels formedfrom a filter media including first panels and second panels, theplurality of filter media panels in overlaying relation to provide thefilter media pack and extending between an outlet face and an inletface, with a flow path running through the filter media from the inletface to the outlet face; plurality of embossments formed in at least thefirst panels, the embossments comprising first embossments and secondembossments, wherein the first and second embossments cover at least 90%of a span between the inlet face and the outlet face to maintain bridgestrength in the filter media pack; wherein the first embossment hasfirst length extending in a first direction and the second embossmenthas a second length extending in a second direction.

The first and second lengths can be linear.

Additionally, the first and second lengths each separately can extend atleast 90% of a span between the inlet face and the outlet face, andwherein the first embossment extends at a different angle than thesecond embossment between the inlet face and the outlet face.

Another inventive aspect of the present invention is directed toward afilter media pack, comprising: a plurality of filter media panels formedfrom a filter media including first panels and second panels, theplurality of filter media panels in overlaying relation to provide thefilter media pack and extending between an outlet face and an inletface, with a flow path running through the filter media from the inletface to the outlet face; a plurality of embossments formed in at leastthe first panels, the embossments comprising first embossments andsecond embossments, the first and second embossment extending less than90% of a span between the inlet face and the outlet face, wherein thefirst embossments cover a span region not covered by the firstembossments such that in combination the first and second embossmentscover at least 90% of a span between the inlet face and the outlet faceto maintain bridge strength in the filter media pack.

In some embodiments, the first embossments extend from proximate theinlet face toward the outlet face but terminate in a middle region ofthe filter media panels, and the second embossments extend fromproximate the outlet face toward the inlet face but terminate in themiddle region of the filter media panels.

In some embodiments, the first embossments and the second embossmentsare linearly aligned with each other between the inlet face and theoutlet face but do not overlap each other in the middle region, and mayconnect into each other.

The first embossments and the second embossments can be arranged offsetfrom each other relative to extend past each other as the firstembossments extend toward the outlet face and as the second embossmentsextend toward the inlet face.

The embossments may also be on different panels, wherein the firstembossments are on the first panels and the second embossments are onthe second panels, although alternatively the first embossments and thesecond embossments are on the same panel as shown in variousembodiments.

In an embodiment for a different strength feature, the first embossmentsextend from a first plane of the first panel into an upstream face ofthe first panel and into a downstream face of the first panel such thatfirst embossments project from both the upstream face and the downstreamface of the first panel, and wherein the second embossments extend froma second plane of the second panel into an upstream face of the secondpanel and into a downstream face of the second panel such that secondembossments project from both the upstream face and the downstream faceof the second panel.

Other aspects, objectives and advantages of the invention will becomemore apparent from the following detailed description when taken inconjunction with the accompanying drawings

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification illustrate several aspects of the present invention and,together with the description, serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a partially schematic side elevation view of a pressed pleatmachine assembly and line that is creating pressed, pleated and embossedfilter media packs, with circles indicating an enlarged portion of thepress and cross-sectional and top schematic views of the embossed andscored and creased filter media sheet;

FIG. 2 is an isometric view of an upper top stamping die in the form ofan embossing plate according to an embodiment of the present inventionthat is usable in the press illustrated in FIG. 1;

FIGS. 3, 4 and 6 are bottom, front and side views of the embossing plateshown in FIG. 2;

FIG. 5 is an enlarged view of a region of FIG. 4 taken about a circle;

FIG. 7 is an isometric view of a lower bottom stamping die in the formof an embossing plate usable in the press shown in FIG. 1 in conjunctionwith the top plate shown in FIGS. 2-6;

FIGS. 8, 9, and 11 are top, front and side views of the bottom embossingplate shown in FIG. 7;

FIG. 10 is an enlarged view of FIG. 9 taken about the indicated circle;

FIG. 12 is an additional perspective illustrations of a bottom embossingplate the same or similar to that shown in FIG. 7 and used or usable inin the assembly and line of FIG. 1, but with additional score barsattached to upstream and downstream sides or ends of the embossing plateto provide a press plate assembly;

FIG. 12a is an enlarged view of FIG. 12 taken about the indicatedcircle;

FIG. 13 is a front view of the respective plate assembly shown in FIGS.12 and 7 with both upper and lower embossing plates illustrated and withupper and lower score bars attached thereto, with the plates shown inthe engaged position with the corresponding embossed features beingreceived into each other and the score features being received into eachother;

FIG. 14 is a cross-sectional view of FIG. 16 taken about line 14-14;

FIGS. 15 and 16 are partially schematic top view and cross-sectionalside view illustrations, respectively, of a pressed media sheet formedthrough the press assembly shown in FIG. 1;

FIG. 17 is an isometric view of a bottom embossing plate similar to FIG.7 and also usable in the press assembly and line of FIG. 1 but that hastapered regions at ends of the embossed groove pattern;

FIG. 18 is an end view of the embossing plate shown in FIG. 17;

FIG. 19 is an enlarged view of a portion of FIG. 17 from a front side;

FIG. 20 is an isometric view of stamping die in the form of a topembossing plate shown in isometric usable with the lower stamping dieshown in FIG. 17;

FIG. 21 is an end view of the upper embossing plate shown in FIG. 20;

FIG. 22 is an enlarged view of a region of the frontal portion of FIG.20;

FIG. 23 is another isometric view of a further embodiment of a bottomgrooving plate usable in the press of FIG. 1 but having wide and narrowV-shape to the embossed groove pattern;

FIG. 24 is an end view of the embossing plate shown in FIG. 23;

FIG. 25 is a front view of a portion of the embossing plate shown inFIG. 23 to better illustrate the wide and narrow V-shaped groove detail;

FIG. 26 is an isometric view of a top embossing plate usable with theembossing plate shown in FIG. 23 also with the widening and narrowing Vgroove feature;

FIG. 27 is an end view of the embossing plate shown in FIG. 26;

FIG. 28 is an enlarged frontal view of a portion of the front of theembossing plate shown in FIG. 26;

FIG. 29 is an isometric view of another embodiment of a bottom embossingplate having a tapering groove profile and that is usable in the pressillustrated in FIG. 1;

FIG. 30 is an end view of the embossing plate shown in FIG. 29;

FIG. 31 is an enlarged front view of a portion of the embossing plateshown in FIG. 29;

FIG. 32 is an isometric view of a top embossing plate usable with theembossing plate shown in FIG. 29, also having the tapering grooveprofile;

FIG. 33 is an end view of the embossing plate shown in FIG. 32;

FIG. 34 is an enlarged front view of a portion of the embossing plateshown in FIG. 32 to better show the tapering groove profile;

FIG. 35 is a schematic illustration of a curved embossing press plateassembly including upper and lower plates shown in a frontal andpartially schematic view according to a further embodiment of thepresent invention that is also usable in the press illustrated in FIG.1;

FIG. 36 is a perspective illustration of an air filter cartridgeaccording to an embodiment that can employ the pleated filter media packcreated according to the embodiments of FIGS. 1, 15, 16 and/or 43, orother such embodiments discussed herein;

FIG. 37 is a top view of the filter cartridges shown in FIG. 36;

FIG. 38 is a partly schematic top view of an embossed and creased filtermedia sheet according to an embodiment of the present invention that maybe made using the press of FIG. 1;

FIG. 39 is a partly schematic top view of embossed and creased filtermedia sheet for making a pleated filter media pack according to anotherembodiment that may be made using the press of FIG. 1;

FIG. 40 is a partly schematic top view of a filter media sheet includingembossments and creases for making a pleated filter media pack accordingto a further embodiment of the present invention;

FIG. 41 is a partly schematic top view of a further embodiment of anembossed increased filter media sheet that has had its edges trimmed andcut away for creating a non-cuboid shape pleated filter media pack;

FIG. 42 is a schematic side illustration of a pleated filter media packshowing that the folds or creases at one end may be pinched closertogether at one of the flow faces as compared to the other flow face toprovide a fan or tapering profile to a filter media pack from one flowface to the other flow face;

FIG. 43 is an isometric view of at least part of a pressed pleatedfilter media pack that can be made in a standard cuboid form made by thepress assembly in line of FIG. 1 according to an embodiment of thepresent invention;

FIG. 44 is an isometric view of an alternative embodiment of a pressedpleated filter media pack according to another embodiment of the presentinvention made by the press assembly in line of FIG. 1 wherein theembossed panel and non-embossed panel have differing lengths to providea non-cuboid shape;

FIGS. 45 and 46 are isometric views of two additional furtheralternative curved pressed pleated filter media packs whereby edges havebeen trimmed via a trimming knife using the trimming option device shownin FIG. 1 and wherein pairs of adjacent panels along the sides and atone of the end faces have been seamed together such as via ultrasonicwelding, and wherein dashed lines in FIG. 46 show where trimming hasoccurred;

FIGS. 47 and 48 are additional isometric views of pressed pleated filtermedia packs having non-cuboid shapes wherein the optional trimming knifein FIG. 1 has been used to trim or cut individual panels into suchshapes to form these shaped packs;

FIG. 49 is an isometric view of yet another embodiment of a pressedpleated filter media pack made by the press assembly in line of FIG. 1wherein the optional trimming device has been used to cut the panels totrapezoidal shape and wherein the sides have been seamed together toform pocket pleats;

FIGS. 50 and 51 are side and isometric views of a further embodiment ofa pressed pleated filter media pack wherein the embossed panels and thenon-embossed panels each vary in size and distance from one side toanother side to provide for a non-cuboid shape;

FIGS. 52 and 53 are another embodiment of a pressed pleated filter mediapack similar to that shown in FIGS. 50 and 51 also with varying pressedembossed and non-embossed panel lengths to provide a non-cuboid shape;

FIG. 54 is a side end view of an embossed pressed pleased filter mediapack whereby the embossments are skewed and do not run perpendicular tothe inlet and outlet flow faces and wherein each panel is embossed withgrooves having a different skew (note a first set of skewed embossmentsshowed in solid lines and a second set of embossments on a panel behindshown in dashed lines) and only two panels of the filter media packbeing shown with solid and dashed lines;

FIG. 55 is an isometric view of a further embodiment of a pressedpleated filter media pack wherein adjacent sets of panels are shiftedrelative to each other such that at least two of the sides arenon-planar;

FIG. 56 is a further embodiment of a pressed pleated filter media packmade by the press assembly line of FIG. 1 where the trimming device isused to trim out part of one of the flow faces and sides and whereinultrasonic welding is used to connect pairs of adjacent pleat panels tothereby provide for pleats and prevent unfiltered air flow through themedia pack;

FIG. 57 is another embodiment of a pressed pleated filter media packshown in a circular shape wherein the trimming tool has been used toshape and cut away the width of adjacent panels to appropriate lengthsto create a circular cylindrical shaped media pack;

FIG. 58 is an isometric view of yet a further embodiment of a pressedpleated filter media pack wherein adjacent sets of panels are shiftedrelative to each other such that two of the sides are non-planar withadjacent panels being rotated relative to each other about an axis thatis perpendicular to the pleat panels;

FIG. 59 is an image of a pressed media pack panel where the panel is aparallelogram and the embossments in the form of grooves are shown to beskewed relative to the plane of the inlet and outlet faces;

FIG. 60 is an isometric illustration of two panels of a pressed pleatedfilter media pack where each panel has embossments and two sets ofembossments and wherein embossments on each panel project in a differentdirection from the plane of the panel;

FIG. 61 is an isometric view of two panels of a pressed pleated filtermedia pack wherein each panel contains embossments and wherein theembossments extend substantially less than a span between upstream anddownstream flow faces and/or creases/folds at opposed ends and alsowhere the embossments or grooves may project from different directionsfrom a plane of each panel;

FIG. 62 is an expanded isometric view of two panels of a pressed pleatedfilter media pack where one panel is pivoted and rotated away from theother panel for illustrative purposes to better show features, andwherein two different forms of tabs, one for pinching and securing pleatpanels together and another that extends from the panel to support anouter perimeter ring seal (that may form a complete ring loop that maybe rectangular or other annular shape) that can be used to seal a filtercartridge against a housing in which a filter element is installed whenin use;

FIG. 63 is an enlarged illustration of a portion of FIG. 62 taking aboutcircle 63;

FIG. 64 is an enlarged illustration of a portion of FIG. 62 taking aboutcircle 64;

FIG. 65 is an isometric view of two panels of a pleated filter mediapack where the filter media sheet has been formed by the press lineassembly of FIG. 1 and wherein integral tabs have been formed into thefilter media shape and that are embedded within an elastomeric seal(that would be understood to form a continuous loop for a housing sealsuch as a rectangular or annular shaped loop), with the adjacent pleatpanels being shown rotated and pivoted away from each other forillustrative purposes;

FIG. 66 is an enlarged view of a portion of FIG. 65 taken about circle66;

FIG. 67 is an isometric view of a side of a pressed pleated filter mediapack made by the press assembly of FIG. 1 and wherein some of theembossments formed also include an embossed graphic such as a writtenstatement for trademark branding or other information;

FIGS. 68 and 69; 70 and 71; and 72, 73 are three sets of differentisometric and end view profiles of portions of filter media sheetsshowing different embossing patterns and profiles that may be formedinto the filter media sheet and used in any of the embodiments disclosedherein;

FIG. 74 is an end view of a portion of a pressed pleated filter mediapack having an embossed panel with grooves according to one pattern thatis attached to and abuts an unpressed planar panel formed into theoverall sheet;

FIGS. 75, 76; and 77, 78 are additional isometric and end views of aportion of a filter media sheet through sections of embossments to showfurther embodiments of embossments usable with any of the foregoingembodiments;

FIG. 79 is an end view of a portion of pressed pleated filter media packshowing two adjacent panels each with embossments in the form oflongitudinal grooves wherein the embossments on adjacent panels arenested within each other in a region formed between adjacent panels;

FIG. 80 is an isometric view of two panels of a pressed pleated filtermedia pack that is particularly useful for pocket pleats wherein curvedembossments in the form of grooves are formed in conjunction with linearembossments in the form of grooves;

FIG. 81 is an isometric view of a panel similar to that shown in FIG. 80but wherein embossments extend from either side of the plane of thepanel;

FIG. 82 is an illustration of a side of a pressed pleated filter mediapack wherein the press panels have embossments projecting a full span ofthe pressed pleated filter media pack between an upstream face and adownstream face and wherein the embossments project from either side ofthe panels from which are embossed;

FIG. 83 is an isometric view of the embossed panel shown in FIG. 82 withthe embossments projecting from both sides in opposite directions fromthe panel;

FIG. 84 is an end view of a pressed pleated filter media pack accordingto a further embodiment wherein a combination of longitudinal groovesand curved grooves are provided in combination and wherein some of thegrooves project from the plane on one side of the embossed panels andother embossments project from the other side of the panels;

FIG. 85 is an isometric view of a panel used in the pack of FIG. 84showing the embossments projecting from both sides of the embossedpanel;

FIG. 86 is a perspective and partially schematic view of an alternativeembodiment of a multiple press machine assembly and line for formingpressed pleated filter media packs;

FIG. 87 is a perspective and partially schematic view of an alternativeembodiment of a indexable press machine assembly and line for formingpressed pleated filter media packs;

FIG. 88 is a perspective and partially schematic view of an alternativeembodiment of a rotating lobbed press machine assembly and line forforming pressed pleated filter media packs;

FIG. 89 is partially schematic, cross sectional view of an alternativeembodiment of a progressive die arrangement that can be employed in anyof the presses shown in FIGS. 1, and 86-88 according to variousembodiments;

FIGS. 90, 91 and 92 are isometric top and end views of an alternativeembodiment of an embossing plate for forming tapering grooves that isusable in the press assembly in line of FIG. 1;

FIGS. 93, 94 and 95 are isometric bottom and end views of a top embossplate usable with the bottom emboss plate of FIGS. 90-92 for formingtapering grooves;

FIG. 96 is an enlarged view of a portion of FIG. 95 taken about theindicated circle;

FIG. 97 is a perspective view of a portion of a pressed pleated filtermedia pack made by the assembly and line of FIG. 1 and having pocketpleats and also ultrasonically point bonded pleat tips in accordancewith further embodiments of the present invention;

FIG. 98 is a perspective illustration of the filter media pack of FIG.97 being made showing the pleat pack and the next hinged embossed panelfor illustrative purposes;

FIG. 99 is a perspective illustration of an embossed pleated filtermedia pack and frame, wherein the media pack is formed via the press ofFIG. 1 or other press embodiments and together forms a brand to provideinformation to the consumer.

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Turning to FIG. 1, the first embodiment of the present invention hasbeen illustrated as an apparatus in the form of a press and pleatmachine assembly line 10, that processes a continuous filter media sheet12 that is being unwound from a filter media roll 14. It is noted that“assembly line” in this context does not mean linear but instead means amanufacturing process in which processing steps are conducted in aseries of different work stations typically in a sequence until a finalproduct is produced. In this instance, the final products produced are aplurality of pleated filter media packs 16 that are delivered onto aconveyor 18 via a shoot 20.

The machine assembly line extends generally between an upstream regionthat includes a media unwind station 22 where the filter media roll 14is placed to allow media to unwind and that is periodically replacedwhen the media roll is exhausted thereby temporarily shutting down theline, toward a downstream region where a pleater such as media packcollector 24 is located. The media pack collector 24 includes a trapdoor 26 to allow a produced filter media pack 16 to ride on the packshoot 20 to the conveyer 18.

In accordance with certain inventive aspects according to certainclaims, the machine assembly line 10 includes between upstream anddownstream regions a press 28 that comprises a cooperating pair ofstamping dies that include an upper stamping die 30 and a lower stampingdie 32. The press 28 further includes a ram 34 that drives the stampingdies 30 and 32 repeatedly into and out of engagement with each otherduring operation. As can be seen in the enhanced circle image, thestamping dies comprise mating female and male embossment features 36that are adapted to form embossments 38 into the filter media sheet 12as also illustrated by enlarged circle views.

The machine assembly line 10 further includes a media conveyingmechanism such as a conveyor such as cooperating rolls 40 that serve toadvance the filter media sheet 12 in a direction from the unwind station22 region toward the region of the pleat collector 24. These cooperatingrolls 40 may be located at multiple locations along the machine assemblyline but in this instance is shown located between the press 28 and thepleat collector 24.

It should be noted that the cooperating rolls 40 do not deform or formthe filter media in an embodiment, but instead will serve to grip thefilter media and move the filter media along a path 42 leading to themedia pack collector 24.

The cooperating rolls 40 may also be chilled to effectively cool theembossed filter media sheet after it has passed through the press 28. Inthis regard, stamping dies may also be heated and are preferably heatedto an elevated temperature as described herein such that during a dwelltime of the stamping dies the filter media is heat-pressed to set andheat-press the embossments 38 into the filter media sheet 12.

Additionally, or in the alternative, an optional oven or heater 44 maybe arranged upstream of the press 28 to preheat the filter media sheet12 and therefore make it more pliable for processing through the press28.

In an embodiment, the press may include a support table 46 upon whichthe lower stamping die 32 is removably mounted and fixed. The lowerstamping die 32 may thus be non-movable during operation.

Further, the ram 34 may include a hydraulic or electrical linearactuator 48 that drives shaft 50 in successive and repeated linearreciprocating movement. Shaft 50 at its end supports and carries theupper stamping die 30 which is driven linearly back and forth in closeproximity to the lower stamping die 32 with the filter media sheet 12trapped and pressed therebetween.

The linear actuator 48 may be supported via a support cage 52 that maybe self-supported or supported more preferably by the table 46 tomaintain the alignment between the upper and lower stamping dies 30, 32so that the respective male and female embossment features 36 in thestamping dies meet in cooperating and receiving fashion into each other.

The press and its linear actuator 48 and the cooperating advance rolls40 may be manually activated in an intermittent fashion whereby duringthe pressing operating the filter media sheet 12 is not advancing alongthe predetermined path 42 but is maintained stationary and when thepress and its stamping dies 30 and 32 are released with a largeclearance gap therebetween, then the cooperating advance rolls 40 may bedriven to advance the sheet to the next embossing location.

More preferably, this is automated and done with a suitable control suchas an electronic controller that may be a software programmed computerand/or a programmable logic controller. Controller 54 is shown to beconnected to the cooperating rolls 40 as well as the linear actuator 48to automate this intermittent activity such that the press is driveninto engagement heat pressing the filter media sheet 12 while thecooperating advance rolls 40 are not in driving engagement. Further, thecontroller 54 maintains the released and separated position of the upperand lower stamping dies 30, 32 while the cooperating rolls 40 are beingdriven. The controller 54 alternates between these two states. Further,the controller 54 will advance the filter media sheet a predetermineddistance each time and may be programmed or selected to provide regularintervals that may be equal intervals or alternatively variable distanceintervals for the various embodiments of filter media packs describedherein.

The controller 54 may also coordinate and actuate an optional roboticpart placer 56 that may be arranged along the line, preferably upstreamof the press 28 to locate and place tabs as herein described in certainembodiments with or without adhesive onto the filter media sheet 12 thatmay then be run through the press 28 and also pressed into engagementfor further securement. Such tabs are optional features used in some ofthe embodiments disclosed herein such as in those embodiments of FIGS.62-64 for example.

The press and upper and lower stamping dies 30, 32 include upper andlower emboss plates 58, 62 and may also include both at upstream anddownstream ends upper score bars 62 and lower score bars 64. The scorebars and the upper and lower emboss plates may provide for plateassemblies. The upper and lower score bars 62, 64 are preferablyprovided to also simultaneously press scores and thereby crease thefilter media sheet 12 both upstream and downstream from the embossments38 in the filter media sheet to form upstream and downstream scores 66,68 that afford the opportunity to provide creases that serve tofacilitate folding of the filter media. Folding at the creases providesthe pleated filter media pack 16 with embossed pleat panels 70 that havebeen pressed and unembossed pleat panels such as flat pleat panel 72that may not have been pressed and preferably are not pressed. As cangenerally be seen, the process forms a continuous sheet of alternatingembossed pleat panels 70 and flat pleat panels 72 that are joined toeach other through upstream and downstream scores 66 and 68 asindicated.

When the desired length of filter media sheet 12 has been generated andpassed through the machine assembly line 10 it may be manually cut ormore preferably cut via an automatic pack cutting knife 74 that may bealso in communication with the controller 54 to cut at appropriate timesrelative to the advancing cooperating rolls 40 that advance the filtermedia sheet along the predetermined path 42. Once the controller 54 hasdriven the cooperating rolls 40 a predetermined distance correspondingto the desired length of filter media sheet 12 usable for the pleatfilter media pack 16, the pack cutting knife 74 may be actuated to cutthrough transversely and preferably perpendicularly to the travel path42 to cut the sheet to length for each of the filter media packs 16.Preferably this is also done during intermittent stoppage but may alsobe operated on a continuous basis in which the knife could move at anangle other than perpendicular to the path 12 to move at the same speedin the direction of the path during cutting.

Another optional feature that may be used in issues to make certainfilter media pack embodiments is a trim knife 76 that may be used totrim one or both of the side edges 78, 80 of the media as schematicallyindicated in FIG. 1. For example, this trim knife 76 may be used to trimedges such as shown in FIG. 41 or as otherwise used to trim edges toform the shapes shown in FIGS. 45-48 for example; as well as additionalembodiments shown for example in FIGS. 56 and 57.

Trim knives 76 may be provided on opposing opposite sides or proximatethe side edges 78, 80 on opposite sides of the filter media sheet 12 toperform these operations. The trim knife 76 may be operated while themechanized media advance roll 40 is operating or alternatively may cutand perform a trimming operation in a mechanized fashion while thefilter media sheet 12 is stopped and during pressing operation of thestamping dies 30, 32 when they are engaged. Greater precision andcontrol of knife 76 can be realized during stoppage.

Additionally, another further optional and desired feature is theability to have adhesive applicators 82 that may also be in electricalcommunication with the electronic controller 54 to dispense adhesivesuch as hot melt, urethane, glue or other such suitable adhesive uponthe filter media sheet 12 at desired locations. The adhesive applicator82 may thus dispense adhesive only while the rolls 40 are advancing thefilter media sheet 12 but advantageously can also be operated during theintermittent stopping to apply adhesive while the filter media sheet isstopped such as applying across the filter media sheet if additionalstitch feeds are desired. The adhesive 82 may also be applied atdifferent locations and there may be more than one adhesive applicator82 such as on opposed side edges 78, 82 that may apply adhesive onopposed side edges 78, 80 of the filter media sheet 12 in order to seamthe side edges and form pocket pleats. For example, the adhesive appliedby the adhesive applicator 82 upon the edges of filter media sheet 12may seam together and form a sealed seam on opposed side edges to ineffect form a pocket pleat such as can be seen for example in theembodiment of FIG. 97. In FIG. 97 adjacent edges of an embossed paneland a flat panel are shown to be seamed together which may beultrasonically bonded or alternatively through adhesive.

Additionally, or in the alternative, the adhesive applicator 84 may alsoapply adhesive at select locations such as shown in FIG. 98 wherevarious dots are illustrated. These dots may be adhesive applicationsfor point bonding or which may alternatively represent ultrasonicbonding locations. This may provide for additional structural integrityto the pleated filter media pack 12 to prevent panels from shiftingrelative to each other during use.

Downstream of the press and optional bonding, various forms of pleatersmay be used including pleat collectors that simply fold the filter mediapack.

One form of pleat collector as illustrated is in the form of anultrasonic plunge welder 84 that works in conjunction with an ultrasonicanvil 86 that are configured with ultrasonic horn features that mate andcontact with each other to ultrasonically bond and weld adjacentportions of the filter media sheet together. The plunge welder 84 andthe anvil 86 may be driven towards and away from each other withadjacent pleat panels 70, 72 therebetween. The plunge welder 84 andanvil may also be used to form bonds at seams and/or form point bondsthrough ultrasonic welding and/or thereby form the features such aspocket pleats as shown in FIGS. 97 and 98. Each of the plunge welder 84and the anvil 86 are movable toward and away from each other and may bemoved away from each other to allow the plunge welder 84 to allowadvancement of pleat panels of the filter media sheet and to weldfeatures upon the immediate pleat panels of the sheet of the in-processfilter media pack 16 that is positioned in media pack collector 24.

The movement of the plunge welder and the anvil may also be coordinatedrelative to the action of the cooperating rolls 40 and may be activeduring intermittent stoppage and can also be operated during advancementof the filter media sheet along the path 42. The plunge welder 84 mayinclude suction and a vacuum on its face in order to pick up andtemporarily secure the pleat panel to itself and facilitates folding ofthe filter media sheet along the upstream and downstream scores 66, 68that are created by the corresponding score features of the upper andlower score bars 62, 64.

Yet another optional feature that may be employed is the ability to usea laminate sheet 88 such as an additional filter media sheet, a scrim, asupport, a screen such as expanded metal for support or other suchlaminate feature which may be desired to be employed. In someembodiments it may be desired to have two layers of filter media sheetto provide for a first level of filtration to capture larger particlesand thereby a less efficient upstream surface to the filter media sheetand a more efficient downstream layer to the filter media. Accordingly,a laminate sheet 88 may be dispensed from laminate roll 90 to overlayeither above or below filter media sheet 12 and also run through thesimilar components including the press 28 of the machine assembly line10. Accordingly, with this configuration the laminate sheet 88 wouldalso be pressed with the same embossment features and embossment 38 asin the filter media sheet 12.

Turning now to FIGS. 14, 15, and 16, the details of the pressed filtermedia sheet 12 formed by the machine assembly line 10 illustrated inFIG. 1 and its component as illustrated in FIGS. 2-13 can be seen withadditional detail. In FIG. 15 it should be noted that only a partialsection of the filter media sheet is shown and break lines on the topand bottom are illustrated to show that additional embossments areplaced side by side. From the foregoing description it will be readilyunderstood how the filter media sheet 12 with the embossments 38 areformed and now detail will be provided to those formed features.

The embossments 38 take the form of projecting ridges 182, when viewedfrom one side such as top side in the case shown in FIG. 15, and thatform corresponding grooves 186 also defined along the underside of theembossments 38 as well as grooves 186 that are formed between theprojecting ridges 182. Additionally, on the bottom side, correspondingridges 182 are formed with grooves 186 on the opposite side.

Typically, the embossments 38 extend a full length of the embossed pleatpanel 70 and between adjacent but spaced flat plate panels 72 as shownin FIGS. 15 and 16, which typically is at least 90% of the length spanof the embossed pleat panels 70 between upstream and downstream scores66, 68 that provide for pivoting hinges at upstream and downstreamlocations indicated at 188, 190. In this manner, the upstream hinge 188allows the upstream flat pleat panels 72 illustrated in FIG. 16 to swingand overlay the bottom side of the embossed pleat panel 70 shown in FIG.16; whereas the downstream hinge 190 is oriented to allow the downstreamflat pleat panel 72 to overlay the top side 184 with the orientationshown in FIG. 16. It is understood that the top side 184 and bottom side185 are reversible in that the top side may be the bottom side and thebottom side may be the top side.

In the elevation indicated in FIG. 16, preferably the upstream hinge 188is located at a different elevation relative to the pivoting hinge whenthe filter media sheet is viewed inside elevation. Specifically, withthe filter media sheet or embossed panel lying flat, the upstream hingeis shown to be positioned below the downstream hinge 190. This allows avertical gap to allow for folding and pleating of the filter media sheet12 to accommodate the height of the embossments 38. Preferably, theupstream and downstream hinges 188, 190 are spaced and separated fromeach other a vertical distance with the orientation shown in FIG. 16preferably at least 50% of height of the embossments and more preferablyat least 75% of the embossments.

Further, the ends of the embossed regions as shown in FIGS. 15 and 16may additionally include tapered ends at the opposite ends of theembossments that lead into and merge into the hinges 188, 190.Additionally, the hinges are also provided with smaller size grooves 194extending perpendicular to the embossments that provide for additionalflexibility in the hinge structure. These grooves 194 may be formed bythe additional triangular groove and triangular ridge projections 174,176 as shown with reference to FIGS. 12 and 13, while the main scorelines 66, 68 can be formed by the triangular ridge and triangular groove170, 172 also shown in FIGS. 12 and 13.

To help facilitate the formation of the tapered ends 192, the embossingfeatures 36 shown on the stamping dies may also have correspondingtapered end sections as shown for example in the embodiment of theemboss plates of FIGS. 17-19.

To recap and provide additional further details on the operation of theassembly line and the method of forming a pleated filter media pack witha filter media sheet, it can be seen with reference to FIGS. 1-16 thatthe method comprises pressing embossments 38 into the filter media sheet12 repeatedly with the stamping dies 30, 31. Thereafter, the filtermedia sheet 12 is pleated utilizing the upstream and downstream scores66, 68 that form corresponding hinges 188, 190 that facilitate foldingand thereby pleating of the filter media sheet into the pleated filtermedia pack 16.

An additional view of such a filter media pack for example is shown inFIG. 43 where it can be seen that this methodology increasing the filtermedia sheet at spaced intervals forms the filter media pack 16 toinclude a plurality of pleat tips 196 at both flow faces 198, 200 inwhich one flow face is the upstream flow face and one face is thedownstream flow face. By creasing the filter media sheet at spacedintervals to form the pleat tips, the embossments 38 can be seen asextending and disposed at least partially between the pleat tips 196 asshown in FIG. 43.

When done in this fashion, where the intervals are uniformly spaced andwith the pleat (e.g. pleat panels) extending between the pleat tips atthe respective inlet and outlet faces, the distance between the pleattips at the inlet face and the pleat tips at the outlet face may remainconstant and thereby form a cuboid shape for the filter media pack 16shown in FIG. 43.

However, with the pressing methodology it can also be accomplished toform the intervals at non-uniform spacing wherein the pleats extendbetween pleat tips at the inlet face and pleat tips at the outlet facewith a distance bearing and creating pleated filter media packs that areirregularly shaped with a region of the inlet face and the outlet faceextending obliquely relative to the extent of the pleat panels 70, 72such as shown in the similar but alternative embodiment of FIG. 44showing a pleat pack 202 where the flat pleat panels 72 are longer thanthe embossed pleat panels 70. Accordingly, the flow faces 204 and 206,while they may extend parallel to each other, extend obliquely and notperpendicular (as in the case of FIG. 43) relative to the embossed pleatpanel 70 and flat pleat panel 72.

In both embodiments of FIGS. 43 and 44, it can be seen that, relative tothe advancement of the filter media sheet 12 along the travel path 42shown in FIG. 1, the extent of the creasing formed by scores and therebythe corresponding pleat tips 196 extend in a direction that istransverse and typically perpendicular to the travel path. Also,advantageously, is that not every panel needs to be processed whichprovides additional speed to the overall process in that the pressing ofthe embossments 38 will be done only into the embossed pleat panels 70and the pressing may be skipped on the flat pleat panels in anembodiment which also causes the first and second embossed and flatpanels to mismatch. This procedure is repeatedly or successivelyconducted to form the overall pleat packs 16 and 202 shown in FIGS. 43and 44 for example.

In a preferred operation of the machine assembly line 10 of FIG. 1, thefilter media sheet 12 is intermittently and successively advanced andstopped along the travel path 42. While the filter media sheet 12 isstopped, the pressing is conducted via the press 28 such that the filtermedia sheet 12 cannot advance if the press is stationary, and while thefilter media sheet is advancing, the filter media sheet passes freelythrough the stamping dies 30 and 32 which are separated by a large gapfor clearance and not in engagement such as shown in the currentcondition in FIG. 1. When the stamping dies come together in the pressedand engaged position though, as shown for example in FIG. 13, that iswhen the filter media sheet cannot pass, travel or advance relative tothe press.

An advantage of this intermittent advancing and stopping operation isthat further operations can be conducted either upstream or downstreamof the pressing dies. While the filter media sheet is stopped, otherprocessing steps and their control are easier and more precise as suchoperations do not need to be moved at the same speed as the filter mediasheet but may be kept in a stationary position without needingcoordination with the speed of the filter media sheet. For example,during stoppage bonding of adjacent pleats formed by pleating can beconducted such as by the plunge welder 84 and anvil 86.

Additionally, or alternatively, during such stoppage of the filter mediasheet, the edges of adjacent pleats may be trimmed to include one orboth of side edges 78 and 80.

Additionally, the pleat tips for at least one of the inlet and outletfaces may be cinched and/or pressed together such as like by ultrasonicbonding that may also be performed by the plunge welder and anvil 84, 86with such features being shown for example in the pleated filter mediapack shown in FIG. 97. Additionally, during stoppage the robotic partplacer 56 may attach components to adjacent panel to provide forstructural support or facilitate better integral attachment of anintegral housing seal as shown with respect to various embodiments.

Preferably, and for the most simplistic type of operation, the upper andlower stamping dies 30, 32 including their respective plates are movabletoward and away from each other with linearly reciprocating movement ofthe plates with the respective female and male embossment featuresreceived into each other with the filter media sheet therebetween. Withthis configuration, the respective plates 58, 60 extend in parallelplanes.

An advantage to using the linearly extending grooves and the linearlyextending ribs to provide for the male and female embossment features asshown in the emboss plates of FIGS. 2-10 is that the correspondingembossments 38 formed into the filter media sheet can maintain aconsistent depth and height for at least 90% of the length of thecentral portions of the embossments that extend between thecorresponding pleat tips that are formed during pressing and pleating.This provides a maximum ridge strength and structural integrity suchthat the pack when formed such as shown in FIG. 43 or 44 maintainsconsiderable strength when subjected to an air flow in application.Specifically, the spacing between the adjacent pleat panels ismaintained during air flow, and the pleats do not collapse or blind offon each other due to the embossments which provide for structuralsupport and integrity of the pleats. This maintains open and good airflow between adjacent pleat panels due to little contact or minimalcontact between adjacent pleat panels to maximize the usage of thefilter media contained within the filter media sheet.

The embossments also provide in effect a corrugation pattern thatprevents the filter media sheet from bending in at least one dimensionproviding for additional strength and support for the pleated filtermedia pack. Thus, by extending the embossments over the full length suchas at least 90% of the length, good structural integrity of the pleatedpack is realized. This is particularly advantageous for deep pleatfilter media packs that have a pleat depth (e.g. span between inlet andoutlet faces) of greater than 6 cm and pleat packs that may be greaterthan 10 cm or even 20 cm or more. Pleat packs may be formed that have apleat depth between 1 cm and 180 cm, but again this is particularlyadvantageous for the deep pleat media packs aforementioned.

Also, during a preferred operation, the filter media sheet 12 is engagedand actively pressed with force between the upper and lower stampingdies 30, 32 wherein the stamping dies can be separated in the engagedand pressing position by a gap equivalent to but more preferablyslightly less than a caliper thickness of the filter media sheet thatmay be a gap of between 80- and 99% of the caliper thickness of thefilter media sheet. This gap can be controlled with stop abutments onthe plates of by way of the amount of pressure applied to the presses inwhich the media content of the filter media sheet limits the pressing.

During pressing, a significant dwell time may occur that is between 0.2-and 300 seconds and preferably between 1- and 15 seconds to ensureadequate formation of the embossments and maintain the shape. This ineffect presses and holds the media to press the features akin to anironing operation.

Also, preferably, the tapered end portion in the form of tapered ends192 are formed into opposed ends of the central portions of theembossments 38 such as shown in FIG. 19, but also shown in the completedfilter media packs of FIGS. 43 and 44 with the tapered end portionsextending toward the respective pleat tips 196. This provides for alarger air flow entrances and air flow exits at the respective inlet andoutlet flow faces 204 and 206.

To facilitate formation of the most advantageous grooves to provide formaximum filtration capacity, the corresponding grooves and ribs of theembossment features on the die 36 and the corresponding embossments 38formed into the sheet press embossments have a length greater than 5 cmwith a width of at least 2 mm and a depth of at least 2 mm. Thesemeasurements are shown in FIGS. 16 and 14 as length L, width W, anddepth D. It is noted that width is measured in these embodiments betweenthe center of adjacent tips of the ridges and the depth is measured fromthe tip of a ridge to a groove bottom.

Preferably, the embossments (and corresponding ridges and/or grooves)have a depth of between 2 mm and 8 mm, and a width of between 2- and 16mm. The length will depend upon the overall span or length of the filtermedia pack between upstream and downstream pleat tips, but typicallycomprises at least 90% of the length as described herein, although otheralternatives are possible.

Additionally, to sufficiently set the pleats and maintain the embossedshape, heating of the filter media sheet for the pressing to atemperature below the glass transition point of the fibers of the mediais conducted such that the fibers are not melted or bonded together dueto the heating of the filter media sheet. For example, the heatingcomprises elevating the temperature of the filter media sheet to between65- and 125° C. for medias that comprise at least 50% cellulose fibersby weight; between 65- and 205° C. for medias that comprise at least 50%fibers by weight including at least one of polypropylene, polyester ornylon fibers. These are typically the most commonly envisioned fibersemployed in a filter media sheet, but additional types of fibers andmaterials may be used including glass fibers and a variety of otherpolymeric materials that are known to one of ordinary skill in the artand/or that are used in conventional filter media sheets. While thepress is preferably heated and heats the filter media sheet and may bethe sole source of heat, additional heating may be conducted such aspreheating the filter media sheet prior to entering the stamping dies.Again, active cooling of the filter media sheet such as by the advancerolls or by running through a cooling station may be conducted afterbeing pressed by the heated stamping dies.

Another advantage of using the press may be realized in certainembodiments, especially with the configuration of the width and depth ofthe embossments in that the filter media sheet can be stretched at theembossments to provide for an increased airflow permeability in thepressed region of the filter media sheet. These pressed regions andembossments may have the fibers pulled apart and not compressedaccording to certain embodiments. Specifically, it has been found that afilter media sheet can be stretched with the fibers slightly separateddue to the pressing operation when compared to the unpressed filtermedia sheet or the unpressed flat panels that are formed betweenembossed panels.

For example, due to the stretching the pressed air flow permeability isat least 110% greater than the unpressed air flow permeability measuredby a TAPPI T251 air flow permeability test. Preferably the pressed airflow permeability may be between 125- and 500% greater than theunpressed air flow permeability.

As a consequence, and when used in the embodiment where there arepressed regions and unpressed regions such as the embossed pleat panels70 and the flat pleat panels 72, different filtering characteristicregions may be formed in the pleated filter media pack. The pressedregion may comprise between 20- and 80% of the pleated filter media packwhereas the unpressed region may comprise the remainder of between 20-and 80%. This provides the opportunity to loosen up a more restrictivemedia and provide for a region that is slightly less efficient but moreair permeable in the embossed pleat panels and a region in the flatpleat panels that are more restrictive to air flow but have a higherefficiency.

In terms of materials, the filter media sheet preferably comprises atleast 10% polymer fibers by weight and more preferably at least 20%polymer fibers by weight and most preferably at least 50% polymer fibersby weight although other possibilities are possible.

The polymer fibers may comprise at least one of a fluorinated polymer,PVDF, polypropylene, polyester and nylon which are common materials usedin filtration medias but again other materials are possible. The filtermedia sheet may also alternatively comprise at least one of thefollowing media fibers: wet-laid microglass, nylon, polypropylene,polyester, wet-laid cellulose and wet-laid polymer. These fibermaterials may be used alone or in conjunction with each other.

The filter media fibers include fibers having a diameter size of lessthan 100μ and preferably less than 50μ and most preferably less than 20μin more efficient medias. These fiber materials may be used alone or inconjunction with each other.

For most typical filtration applications, the filter media sheet 12prior to pressing has an air flow permeability of between 2 and 400 CFMfor most filtration applications (including liquid filtration at thelower range end), and more preferably between 10 and 150 CFM for mostair filtration applications (measured by ASTM D737-04(2012) standard,commonly tested with TEXTEST Model FX3300 instrument); and an initialgravimetric efficiency of between 50% and 100% for ISO 12103-1, A2 FineTest Dust made by Powder Technologies having a location in Arden Hills,Minn. (measured by ISO 5011 standard), and a caliper thickness ofbetween 0.2 and 7 millimeters, and more preferably between 0.2 and 1millimeters.

Turning now to FIGS. 2-5 and FIGS. 7-10, the cooperating and matingupper and lower emboss plates 58 and 60, as employed in the press 28shown in FIG. 1, are shown in larger and greater detail. In FIGS. 2-5,the upper or top stamping die in the form of embossing plate 58 isillustrated to include a planar body in the form of a flat plate 100into which a plurality of embossment features 36 are formed to include aplurality of teeth and ridges 102 and grooves 104 that extendlongitudinally between an upstream end 106 and a downstream end 108. Thegrooves 104 extend generally parallel and in spaced relation and areformed between the ridges 102 in this embodiment. The teeth and ridges102 and the grooves 104 are sized and configured to be closely receivedwithin corresponding grooves and ridges formed on the bottom embossplate 60 shown in FIGS. 7-10 (see description below).

The upstream and downstream ends 106, 108 preferably have a plurality ofbolt holes 110 that allow for attachment of score bars as can be seenfor example in FIGS. 12 and 13. Additionally, bolt holes 112 areprovided for receiving bolts that provide for attachment to the carriage31 of the upper stamping die (See FIG. 1.)

Longitudinal and extending holes extend between front and back sides114, 116 and are indicated as heating channels 118 that can eitherreceive a heating element or alternatively be hooked up to a fluidcircuit to circulate hot fluid to facilitate heating of the emboss plate58 to the desired temperature to facilitate heat pressing of the filtermedia sheet.

Further, pilot structures 120 may be provided that interact and alignwith corresponding pilot structure on the upper stamping die carriage 31to facilitate better alignment and precise alignment of the upper embossplate 58 relative to the lower emboss plate 60 of the lower stamping die32 shown in FIG. 1.

Turning then to FIGS. 7-10, the lower emboss plate 60 is illustrated ingreater detail which is quite similar to that of the upper emboss plateshown in FIGS. 2-5 and is configured to matingly receive with the upperemboss plate with the teeth and ridges of the upper emboss plate beingreceived within the grooves of the lower emboss plate and the teeth andridges of the lower emboss plate being received within the grooves ofthe upper emboss plate. It is also understood that the lower embossplate rather than being mounted to the upper stamping die carriage wouldbe instead nested and received within a fixture 33 of the lower stampingdie 32 shown in FIG. 1, which may simply be the table top or otherstructure mounted on table 46 shown in FIG. 1.

In FIGS. 7-10, the lower or bottom stamping die in the form of embossingplate 60 is illustrated to include a planar body in the form of a flatplate 130 into which a plurality of embossment features 36 are formed toinclude a plurality of teeth and ridges 132 and grooves 134 that extendlongitudinally between an upstream end 136 and a downstream end 138. Thegrooves 134 extend generally parallel and in spaced relation and areformed between the ridges 132 in this embodiment. The teeth and ridges132 and the grooves 134 are sized and configured to be closely receivedwithin corresponding grooves and ridges formed on the top emboss plate58 shown in FIGS. 2-5 (see description above).

The upstream and downstream ends 136, 138 preferably have a plurality ofbolt holes 140 that allow for attachment of score bars as can be seenfor example in FIGS. 12 and 13. Additionally, bolt holes 142 areprovided for receiving bolts that provide for attachment to the table inFIG. 1

Longitudinal and extending holes extend between front and back sides144, 146 and are indicated as heating channels 148 that can eitherreceive a heating element or alternatively be hooked up to a fluidcircuit to circulate hot fluid to facilitate heating of the emboss plate60 to the desired temperature to facilitate heat pressing of the filtermedia sheet.

Further, pilot structures 150 may be provided that interact and alignwith corresponding pilot structure on the table and fixture tofacilitate better alignment and precise alignment of the upper embossplate 58 relative to the lower emboss plate 60 as shown in FIG. 1.

Turning to FIGS. 12-13 it can be seen that upper and lower score bars62, 64 are removably and adjustably mounted to both the upper and loweremboss plates 58, 60 by way of bolts 152 that are shown in FIG. 13. Thescore bars include oblong adjustment slots 154 that allow the score barsto be moved vertically upward and downward to allow positioning of thescore lines when conducted on the filter media to be at a higher orlower end relative to the embossments that are formed, which isadvantageous in pleating operations of the embossed pleats formedherein. Further, it can be seen that when engaged as shown in FIG. 12athere exists a gap 156 between the upper and lower score bars 62, 64 toaccommodate the filter media sheet.

In this regard, it should also be appreciated that the respective teethand ridges 102, 132 and corresponding grooves 104, 134 of the upper andlower emboss plates 58, 60 when engaged do not contact each other, butinstead there is a similar gap to gap 156 that can in some embodimentsbe formed due to the fact that the upper and lower emboss plates 50 and60 have corresponding abutment surfaces 122, 124 both on front and backends that run traverse and preferably perpendicular to the score barsthat will contact each other before bottoming out occurs to ensure a gapthat is of the desired width to accommodate the filter media sheet.Additionally, shims may be placed on either or both of the abutmentsurfaces 122, 124 and form the abutments to adjust the gap accordingly,to accommodate different filter media caliper thicknesses.

With continuing reference to FIGS. 12 and 13, it can be seen that theupper and lower score bars 62, 64 are each made of similar andindividual and cooperating score bar members 158, 160, either which maybe an upper or lower score bar. Score bar member 158 includes a groove162 that receives a projection 164 extending from the other score barmember 160.

Further, a preferred configuration formed on the outside surface of thecorresponding groove and projection includes tapering walls includingtapering walls 166 formed on the grooved score bar member and taperingwalls 168 formed on the ridged score bar member 160 that match and alignwith the tapering walls 166 such that a consistent gap 156 is maintainedtherebetween.

Additionally, within the groove and projection features, additionalgrooves and projections are provided. For example, the grooved score bar158 also includes a central projection in the form of a triangular ridge170 that is configured to form a corresponding score line to form acorresponding hinge in the filter media sheet for forming pleats. Thetriangular ridge is received within a corresponding triangular groove172 that is formed within the projection 164 of the ridged score barmember 160. Additionally, on either side of the triangular ridge, a pairof triangular grooves 174 are provided that receive the correspondingpair of triangular ridge projections 176 from the other score barmember. These create additional flexibility if desired in the overallhinge structure of the filter media sheet when used to form a pleatedfilter media pack.

As can be seen, the grooved score bar members 158 are provided asattached to the lower emboss plate 60 of the downstream end with theridged score bar member 160 attached to the upper emboss plate 58; whileon the upstream end 106, 136 the grooved score bar members 158 areprovided as attached to the upper emboss plate 58 with the ridged scorebar members 160 connected to the lower emboss plate 60. By virtue ofthis configuration, the hinges are inverted one another when formed intothe filter media sheet as will be seen with reference to FIG. 16.

While the abutment surfaces 122 and 124 may stop and thereby provide alimit to a maximum amount of compression, the stop and abutment surfaces122 and 124 may not come into contact with one another, but may actuallybe separated by a gap even when in the pressed and engaged position withthe filter media sheet being pressed by the embossment features 36 ofthe respective upper and lower stamping dies 30, 32. In particular,rather than controlling the gap or thickness by contact with theabutment surfaces 122, 124, the ram 34 and its linear actuator 48 mayhave a predetermined or preset pressure to provide a predeterminedpressure in pounds per square inch to the filter media sheet.

The filter media sheet typically does not extend over the abutmentsurfaces 122, 124 in a preferred embodiment, although other alternativesare possible, including having trimming knives that engage on theabutment surfaces. By using a controlled pressure, a desired amount ofstretch may be imparted to facilitate stretching of fibers and increasedair flow permeability to provide a filter element that may have anincreased life span due to the increased air flow permeability. Thereason is that filter expiration for lifespan is often determined by therestriction or pressure drop at predetermined air flow parameters. Byopening the media through stretching and providing for increased airflow permeability, that will delay the point in which a filter reachesthe restriction or pressure drop thereby extending the overall life ofthe filter and its lifespan.

Further, to form the filter media sheet having the width, depth andlength dimensions shown in FIGS. 14, 15 and 16 it will also beappreciated with reference to FIGS. 5, 6, 10, and 11 that the same widthand length and depth dimensions will also apply to the teeth andcorresponding grooves on the upper and lower emboss plates 58 and 60.This makes sense because the shape of the embossed features 36 in thestamping dies generally match the embossments 38 formed in the filtermedia sheet. However it is noted that in the filter media sheet, and dueto flexibility and some memory of the filter media that the edges andfeatures of the filter media including the corresponding ridges andvalleys such as grooves, may not have sharp corners but may be morerounded in profile. Referring back to FIGS. 10 and 11, it can generallybe seen that the shape of the grooves include the maximum width(designated as width W measured between peak tips of ridsges), but alsohave a groove bottom which defines a minimum width Wmin that in anembodiment may be 20- to 50% of the normal width W. Additionally, eachof the teeth or ridges 102 has a tip having a width Wt that is smallerthan the width Wmin to allow room for the filter media to pass alongeither side of the teeth without being cut or rendered non-functional.Typically, the tooth width Wt is less than 75% of Wmin and typically 50%or less in various embodiments herein, but the ultimate shape orthickness will depend in part upon the desired caliper thickness of thefilter media sheet being run. As shown in the first embodiments shown inFIGS. 2-13, the bottoms of the grooves 104, 134 may be flat and the tipsof the teeth and ridges 102, 132 may also likewise be flat.

Turning next to the emboss plates shown in FIGS. 17-22 according to yetanother embodiment of the present invention, it will be understood thatthese emboss plates 210, 212 are structurally the same as those shown inthe corresponding embodiments of FIGS. 2-13 and also usable in the press28 of FIG. 1 such that the afore-described features of the priorembodiments are applicable to this embodiment as well. However,additional features and distinctions will be discussed below.

As can be seen in FIGS. 17 and 18, emboss plate 220 is formed with anadditional feature in the form of tapered ends 214 that are formedintegral with the embossing feature and at corresponding upstream anddownstream ends of the emboss plates. Further, the teeth tips may alsoinclude a non-flat feature such as a linearly extending indentation 216that may have some advantages with certain medias. Turning to FIG. 20,the emboss plate 212 matches and mates with the emboss plate 210 asshown in FIG. 17. This emboss plate 212 is similar to those of previousembodiments, but it is noted that the pleat tips while flat do not havesharp corners but are rounded at rounded tips as shown in FIG. 22.

Turning next to FIGS. 23-28, further embodiments of cooperating andmating emboss plates 220, 222 are illustrated that also include aV-shaped or tapering groove profile according to a further embodiment ofthe present invention. It will be understood that emboss plates 220, 222are structurally the same as the embodiments of FIGS. 2-13 and alsousable in the press 28 of FIG. 1, such that the afore-described featuresof the prior embodiments are applicable to this embodiment. However,additional features and distinctions will be discussed below.

The primary additional distinction and feature is that each embossmentfeature tapers from upstream and downstream ends with a widening Vprofile at the upstream or inlet face (as well as the outlet face) inthe eventually formed media pack to allow for greater air flow into thefilter media pack and thereby funnel airflow into the media pack.Specifically, it can be seen that groove sidewalls 224 taper from theupstream end to the downstream end as shown in FIG. 25 thereby providinga narrower groove width at one end as compared with the other for theemboss plate 220. Similarly, the corresponding and matching emboss plate222 also has tapering groove sidewalls 226 as shown in FIG. 28. Thegrooved sidewalls 224, 226 thus do not extend parallel to the travelpath 42 when employed in the press 28 of FIG. 1, but extend at anoblique path to provide for the tapering grooves. Further, it is notedthat with this profile some of the embossments and their defined groovesformed in the resulting filter media pack will have a wider opening atthe inlet end while some of the grooves will have a wider opening at theoutlet end.

Turning next to the embodiment of FIGS. 29-34, further embodiments ofemboss plates 228, 230 are illustrated, where it is understood thatthese are structurally the same as the embodiments of FIGS. 2-13 andalso usable in the press 28 of FIG. 1, such that the afore-describedfeatures of the prior embodiments are also applicable to thisembodiment. However, additional features and distinctions will bediscussed.

Referring to these figures, it can be seen that a tapering group profileand tapering tooth profile is provided for both of the emboss plates228, 230. Specifically, it can be seen that the groove bottom and teethtips 232, 234 each taper from one of the upstream and downstream ends tothe other end of the emboss plate 228 which provides for taperingsidewalls 236 between upstream and downstream ends. As can be seen, thegroove bottom and teeth tips may also be rounded in this design, but itcan also be seen that the groove bottom width Wmin in this embodimentvaries and widens from one end to the other and narrows from that end tothe first, as depicted in FIG. 31. Additionally, the same and matchingfeatures apply to emboss plate 230 shown in FIGS. 32-34 with similarvariable width groove bottoms, 238 variable width teeth tips, 240, andtapering sidewalls 242.

Turning next to FIG. 35, a further embodiment is illustrated in partlyschematic form of upper and lower emboss plates 244, 246, that are alsostructurally the same as the embodiments of FIGS. 2-13 and also usablein the press 28 of FIG. 1 such that the afore-described features of theprior embodiments are applicable to this embodiment. However, additionalfeatures and distinctions will be discussed. The upper and lower embossplates 244, 246, in this embodiment, have a curved profile to providecurved male and female embossment features, including curved embossmentfeatures 248, 250 on the respective plates that also extend betweenupstream and downstream ends where respective score bars 252 areschematically indicated. One of the plates has a concave press surfacethat receives and provides a nest for the convex press surface 256. Anadvantage of using this design is that it may also impart a non-planaror curvature to the resulting filter media pack and filter media sheetto form the filter media sheet yet in a further dimension in addition tothe dimensions conducted by the embossments.

Yet a further embodiment of emboss plates 260, 262 are illustrated inFIGS. 90-96 where it will be understood that these are structurally thesame as the embodiments of FIGS. 2-13 and also usable in a press 28 ofFIG. 1, such that the afore-described features of the prior embodimentsare also applicable to this embodiment. However, additional features anddistinctions will also be discussed.

In this embodiment, a unique pattern of tapering grooves andcorresponding tapering teeth 264, 266 are provided in emboss plate 260with the depth of the tapering grooves and width of the tapering groovesboth varying as the plate extends from one end to the other. It can beseen that a first set of tapering grooves narrow in width and depth froman upstream end to the downstream end, while a second set of taperinggrooves narrow in depth and width from the downstream end to theupstream end. Further, the mating emboss plate 262 has tapering profiledteeth 268 that are adapted to be received in the tapering grooves 264with narrow slit grooves 270 illustrated, for example, in FIG. 96.

Turning next to FIGS. 38-41, it can be seen that various forms ofembossments and profiles may be created into the filter media sheet 12using the machine assembly line 10 of FIG. 1. It will be understood thateach of the embodiments shown in FIGS. 38 and 41 is structurally similarto the embossed sheet that is shown in FIG. 1 and, accordingly, theafore-described features of the prior embodiments are also applicable tothese embodiments. However, additional features and distinctions willalso be discussed.

Turning first to FIG. 38, an embossed filter media sheet 272 isillustrated to include embossed and non-embossed, unpressed or flatpanels 276 which are separated from one another by full creases dividedby score lines 78. Embossments are provided which define grooves 280which are schematically indicated and run perpendicular relative to thescore lines 278. However, the grooves in this embodiment only extend apartial span between upstream and downstream score lines 278 of theembossed panels 274. Thus, these are only partial length grooves 278rather than full length grooves. However, the grooves overlap and afirst set of the grooves 280 extend from the upstream score line to anoverlap in a middle region with a second set of grooves 280 which extendfrom the downstream score line 278. These grooves may terminate at least15% short of the upstream or downstream crease created by the respectivescore lines. As a result, an upstream set and a downstream set ofgrooves are laterally offset from each other, but have overlappingportions such that in any plane perpendicular to the travel direction ofthe media during pressing, the plane extends at least through one of theupstream and downstream sets of grooves to provide a continuous bridgestrength through a middle region of the embossed sections, thuscollectively the grooves and embossments extend at least 90% of thelength or span between creases when two adjacent grooves or embossmentsare considered together. With this configuration, less of the sheet mayneed to be embossed and the grooves also do not need to extend fullywhich allows for more open flow in some embodiments.

FIG. 39 is a schematic illustration of the embossed filter media sheetshown in FIG. 1 and accordingly no additional description isnecessitated.

FIG. 40 shows another embodiment wherein at least two different pressstations and presses 28 would be utilized in the machine assembly line10 of FIG. 1, and in series to facilitate stamping of alternatinggrooves into the embossed filter media sheet 282 shown in FIG. 40.Specifically, embossed filter media sheet 282 includes a first set ofembossed panels 284 with schematically indicated embossments defininggrooves 286 that extend longitudinally between creases 288 whichfacilitate pleat folds; and a second set of embossed panels that havetransverse grooves 292 extending in a different direction fromlongitudinal grooves 286 and that may run parallel with the creases. Thelongitudinal grooves 286 run transverse to the creases and preferablyperpendicular to the creases 288 in this embodiment. This providesbridge strength in two dimensions and better ensures and preventsblinding off during fluid filtration.

Turning to FIG. 41, embossed filter media sheet 294 is provided that isthe same as that of FIG. 39, and of the embodiment shown in the machineassembly line 10 of FIG. 1, but in which the trimming operation has beenused to cut from opposed side edges 78, 80 at cut lines 296, 298 usingthe trim knife 76 shown in the machine assembly line 10 of FIG. 1.Trimmed segments 300 are removed from the embossed filter media sheet294. This can be employed to create unique and different shapes. Whilewedge-shaped trimmed segments 300 are shown in FIG. 41 more typically,stepped segments will be conducted whereby the shape of the embossedpanel will match that of the flat panel to create any of the shapes inFIGS. 47, 48, 49, 56, and 57 for example. Two adjacent panels willtypically have the same cut profile (not shown in this embodiment butshown in FIGS. 45-49 for example). Thus, the cut lines 296 and 298 andresulting trim segments 300 can be adjusted or coordinated to thedesired shape of the filter media pack according to the embodimentsshown in FIGS. 47, 48, 49, 56, and 57.

Turning to FIG. 42, a schematic side illustration of a filter media pack302 is illustrated having an upstream flow face 304 and a downstreamflow face 306 for fluid flow. The pleat tips 308 at the downstream face306 are pinched together and may even compress the embossments slightlyto provide for a narrower width at the downstream flow face 306 ascompared to the upstream flow face 304. The upstream flow face mayalternatively or additionally be fanned out such that adjacent panels orsets of embossed panels do not touch each other; whereas at thedownstream flow face, all of the panels are in contact with each other.This may be facilitated by the fact that the grooves and strengthafforded by the filter media allow for this feature to be implementedwithout requiring additional structural support. This may beparticularly advantageous in an air cleaner housing where there may bemore room at an upstream end than a downstream end while being able toallow for increased flow area at the upstream end. Spacers may beinstalled at the upstream end to fan out pleats and maintain spacing.

Turning then to resulting filter media packs that may be achievedthrough trimming attention will now be directed towards the additionalembodiments of FIGS. 45-58, one of ordinary skill will understand thatin each of these embodiments they are structurally the same as theembodiment shown in FIGS. 1, 43, and 46 and also usable in being madewith the press 28 and assembly line 10 of FIG. 1, such that theafore-described features of the prior embodiments are also applicable tothese embodiments and like numbers may be used for greater understandingas done throughout. However, additional features and distinctions willbe discussed.

Turning to FIGS. 45 and 46, curved filter media pack 310, as shown inFIG. 45; and curved filter media pack 312 as shown in FIG. 46, areillustrated and are much the same other than the media pack 310 shown inFIG. 45 has a displacement of 45° between the inlet face and the outletface whereas in the embodiment of FIG. 46 the curved filter media pack312 has a displacement between the inlet face and the outlet face of90°.

Both of these embodiments are made and created with similar methodologyas such attention will be focused upon that the embodiment of FIG. 46understanding that the same description applied to FIG. 46 is alsoapplicable to FIG. 45. In making the filter media pack 312, theembossing features on the respective stamping dies employed in theassembly line of FIG. 1 do not extend linear but extend along a curvedpath to form corresponding curved embossments to define curved ridges314 and curved grooves 316 extending between two flow faces 318, 320wherein one of the flow faces is an inlet face and the other being anoutlet face. At flow face 318, scores 322 are provided which definecreases and folds between emboss plate panels 324 and an unembossed orflat plate panels 326 thereby providing a plurality of pleats which inthis embodiment form a plurality of pocket pleats 328. As can be seen,the flow faces 318, 320 may be flat in the aggregate (i.e. able to lieflat) and similarly two side faces are flat side faces 330, 332 are inthe aggregate flat (the back side face 332 being the back side of thelast flat pleat panel 326 with the front flat side face 330 being theembossed pleat panel 324). In contrast the other two sides are curvedsides 334 and 336 that extend from one flow face 318 to the other flowface 320 and transversely between the flat side faces 330, 332.

Preferably, the shape of the curved ridges, 314 and curved grooves 316match the curvature of the curved sides 334, 336.

To create this filter media pack preferably the trim knife 76 isutilized to cut away regions of each emboss plate panel 324 and flatpleat panel 326 as indicated by dashed cut-away regions 338, 340 thateach indicate the section of each panel that has been cut away to formthe curved shape. Additionally, in order to form pocket pleats, adjacentpairs of embossed and flat pleat panels 324, 326 are seamed together andbonded together through adhesive and/or ultrasonic welding at curvedseam 342, and curved seam 344 to avoid unfiltered air flow through theseseams and to ensure that as fluid travels from one flow face to theother flow face that filtration occurs and no unfiltered air flowtravels through the curved filter media pack 312. Additionally, thecrease at the other flow face 320 is created by an end seam 346 tocomplete the pocket pleats 328 which is also performed by the ultrasonictool (e.g. the plunge welder 84 and anvil 86 as shown in the machineassembly line 10 of FIG. 1) or created via the adhesive applicator inwhich adhesive is applied to join adjacent pairs of individual pleatpanels.

It can be seen with the embodiments shown in FIGS. 45 and 46 that thelength of the grooves can extend between the first end face and thesecond end face with the grooves making a turn of at least 20° and theoverall filter media pack also making a turn of at least 20°. This maybe advantageous in various applications where space is limited or needsto make a turn such as in various engine filtration applications whichallows for flexibility of design to accommodate other engine componentsaround the filter (e.g. such as a pipe or duct).

It will also be appreciated that in this embodiment pocket pleats maynot be necessitated but instead alternatively, the curved sides 334 and336 may alternatively be formed with molded side panels to preventleakage or seal off those side faces similar to as is done in theembodiment of a completed filter media pack with sealing system asindicated in FIG. 36 for example.

Turning to FIGS. 47 and 48, two additional irregular-shaped filter mediapacks 350, 352 are illustrated in which the flow faces arenon-rectangular. For example in the regular filter media pack 350, theflow faces 354 are formed via a cut line 356 by virtue of the trim knife76 employed in the machine assembly line 10 of FIG. 1. This embodimentdoes include a cuboid portion 358 and a non-cuboid portion 360 thattogether make up the overall irregularly-shaped filter media pack 350.It can be seen that the embossments also run transversely and preferablyperpendicularly to the flow faces 354 in this embodiment. In the cuboidportion 358, the trim knife 76 may not be necessitated for use but isnecessitated for use in creating the non-cuboid portion. The outerperipheral sides 162 of media pack 350 which includes some planar facesand the curved portion may be mounted with a suitable frame and adhesiveattachment or can be over-molded if desired to prevent unfiltered airflow when fluid flows between the respective flow faces 354. Theirregularly-shaped filter media pack 352 of FIG. 48 is much similar tothat of FIG. 47 other than the shape being different such that theaforementioned description is applicable to FIG. 48 other than the shapevariation. It is seen in FIG. 48 that a V-shaped filter media pack maybe achieved as an alternative. This emphasizes the flexibility anddesign in that it may take a variety of shapes from cuboid shapes tonon-cuboid shapes and allow for design variation to fit a variety ofdifferent housing configurations.

Turning to FIG. 49, a further embodiment of a filter media pack 166 isillustrated that is quite similar to that of FIG. 43 and as such thesame description thereto is applicable but in this case the trim toolknife 76 of FIG. 1 is used to cut a different shape to make one flowface 168 of a different shape than a second flow face 170 by cutting atleast one side to provide one or more tapered sides.

In this manner, the filter media pack 166 takes the form of atrapezoidal shape. Again the tapered sides may be sealed and over-moldedif desired or pocket pleats can be formed by seaming adjacent pleatpanels if desired.

In the embodiments of FIGS. 50-53 additional media packs 174 and 176 areprovided in which respective flow faces 178 (shown in FIGS. 50 and 51)and flow faces 180 (shown in FIGS. 52 and 53) while planar are notparallel with each other. This can be accomplished by varying the heightof the pleat which is allowed and permitted in that the filter media maybe advanced a predetermined distance as desired. Additionally, ratherthan just simply having one press station, and press 28 as indicated inFIG. 1, a series of presses 28 may be provided, one for each differentlength of embossment provided to facilitate the variable length and spanof the filter media pack and embossments between the respective flowfaces 178 shown for FIGS. 50 and 51 and flow faces 180 shown for FIGS.52 and 53. These filter media packs 174, 176 may also be fitted with anouter frame or wrap structure such as shown in FIG. 36 and facilitatedwith a housing seal as also shown for FIG. 36.

Turning to FIGS. 36 and 37 a perspective and top view of a replaceablefilter cartridge 382 incorporating the pleated filter media pack 16 isillustrated that is usable for a replacement filter to filter air in anengine air filtration application such as being installed in an aircleaner housing (not shown) and sealed against a corresponding sealingsurface of such an air cleaner housing. It is also understood that anyof the filter media packs such as shown in FIGS. 43-58 may also beequipped with the same component with the shape of the side panels andseal configured to fit in surrounding relation for example of suchfilter media pack to the desired shape, such that the teachings anddisclosure pertaining to this embodiment are applicable to the otherembodiments of other shaped filter media packs disclosed herein tocreate filter cartridges that are usable in air cleaner housings and/orthat can be connected to an fluid filtration circuit.

In this embodiment, the filter cartridge 382 employs a cuboid andrectangular filter media pack such as the filter media pack 16 createdfrom assembly and line of the first embodiment of FIG. 1 and asrepresented by the filter media pack 16 in FIG. 1 and FIG. 43(understanding that the media pack 43 would have additional pleats overa lateral span to fill the square shape shown for the media pack 16 inFIG. 36). As shown therein, the filter media pack 16 includes integrallymolded and molded-in-place side panels 384 on first and second oppositesides and that are integrally bonded and imbedded with correspondingside edges 78, 80 of the filter media sheet on opposed sides of thepleated filter media pack 16. It can be seen that these side panels 384cover the full length of the sides between the opposed flow faces toprotect and seal the opposed sides of the media pack where the raw edgesof the emboss plate panels and the flat pleat panels are located. Bysealing it is meant that the flow of unfiltered fluid is not allowed topass through the side edges when installed in an air cleaner housing.

A relatively hard material of polyurethane may be used for the sidepanels 384 to provide for additional support.

Additionally, the fabricated side panels 386 in the form of fiber board,plastic, metal or other rectangular shaped panels may optionally beattached in covering relation to the embossed pleat panels or flat pleatpanels at the other two opposed sides that extend perpendicularly to themolded-in-place side panels 384. The prefabricated side panels 386 areembedded within during the integral molding of side panels 384 toencapsulate these and provide for sealing relationship. Theprefabricated side panels 386 may be attached and sealed along theirentire lateral span with suitable adhesive such as polyurethane toattach and seal the side panels 386 to the opposite sides of the mediapack in a manner that prevents flow of unfiltered air flow from one flowface 198 to the other flow face 200.

Alternatively, panels 386 may also be molded like panels 384 and alsoformed of polyurethane or other molding material.

Additionally, filter media cartridge 36 is provided with a housing seal388 that may be a prefabricated seal that is glued and sealed around theperiphery of side panels 384 and 386 in a manner that preventsunfiltered air flow through the filter cartridge from the inlet face tothe outlet face or that is molded and placed around the outer peripheryof side panels 384 and 386.

For example, housing seal 388 may comprise elastomeric material such aspolyurethane, nitrile, rubber or other such elastomeric material that issuitable for providing either an axial seal or radial seal with ahousing.

In an embodiment, the housing seal 388 is made of a material that issofter and more elastomeric than the harder material of side panels 384and the side panels 386 which may also be formed of elastomericmaterials such as polyurethane.

In another embodiment, the housing seal 388 may be integrally formed atthe same time and/or formed of the same durometer material as the moldedside panels 384.

It is also understood that rather than providing separate side panels384 and 386 that side panels 384 and 386 may instead be a prefabricatedrectangular casing that has a rectangular opening and void for receivingthe filter media pack 16 in which the filter media pack 16 would beadhesively attached and sealed around its periphery to such rectangularprefabricated housing. As such, side panels 384 and 386 may also be forexample a prefabricated plastic or metal or paperboard or cardboardrectangular shell in the form of a casing that takes the same shape asthat of the media pack and receives the media pack therein. Such a shellin the form of a casing may then also provide a structure for supportinga seal or providing for integral molding of a seal thereto to providefor the housing seal 388.

A wide variety of fluted filters, direct flow filters, panel filters andpanel filter casings are known in the art, and the media packs of theembodiments herein can be used to replace those while using the samecasings and sealing systems of those prior systems.

Turning to FIG. 54, another embodiment of a pleated filter media pack390 is provided wherein each of the panels are embossed such as wasshown for example in FIG. 40 but wherein the adjacent panels definedifferent sets of embossments which in this embodiment includes firstskewed embossments 392 extending from an inlet face 396 to an outletface 398 and a second set of skewed embossments 394 that also extendfrom an inlet face to an outlet face. However the first and second setsof skewed embossments extend at different angles as can be seen. Itshould be noted that the embodiment of FIG. 54 is viewed from a side ofthe filter media pack 390 such that the first set of skewed embossments392 are shown on the side face of the structure and the second set ofskewed embossments 394 are on the very next panel behind and thereforeshown in dashed lines. With this arrangement, each panel may be embossedand this also provides for additional structural support in thatembossments are extending in two different directions and further eachpanel is embossed to provide structural support. Further, an advantageof this design is that the angles provide different dimensions ofstructural support not realized when embossments only extend in onedirection. It will be understood that the pleated filter media pack 390shown in FIG. 54 may be of a cuboid shape and therefore also used oremployed in a similar manner such as pleated filter media pack shown forexample in FIG. 1 or 43 for example.

Turning to FIG. 55, another embodiment of a filter media pack isillustrated and that can be created using the filter media pack 16 shownin FIG. 1 but wherein individual panels are shifted to create a curvedpleated filter media pack wherein the front pleat panel 402 is shiftedfrom intermediate panels and the back pleat panel 404 to provide opposedmatching curved sides 406 that are formed via the side edges 78, 80 ofthe filter media sheet. As a result, two of the sides extending betweenflow faces 408 are the curved sides 406 shown and two of the sides areflat sides provided by the front pleat panel 402 and back pleat panel404 in that these will generally lie flat along a surface even ifembossed. When in use, and jacketed or employed in a housing shelland/or molded panels carrying a seal, flow will flow between the flowfaces 408 to filter fluid flowing therebetween.

Turning to FIG. 56, a pleated filter media pack 410 is illustrated thatis the same as that coming off the line for pack 16 except that anirregular corner portion 412 has been trimmed away via the trim knife 76option of the line assembly of FIG. 1 to disrupt the otherwise cuboidshape of the media pack 410 in this embodiment. Removal of the cornerportion 412 provides for a void that can receive for example a pipe,duct, engine assembly or other component and may allow for the filterhousing in which it is installed to also include or accommodate such ashape that may allow for other engine components to protrude up intowhat would otherwise be a rectangular cuboid filter housing. This way,space which is limited under the hood in many engine applications can beaccommodated by allowing for components to project up into areas thatwere not possible due to the previous cuboid or cylindrical shape of anair filter housing. In this embodiment, one flow face 414 is rectangularwhile the other flow face 416 is irregular. The irregular flow face 416can be made and accomplished via the welding and anvil tool which joinsand seams adjacent pleats providing for pocket-like pleats to finish upand seam the pleat edges and creases along the irregular flow face 416as described above for other embodiments.

FIG. 57 illustrates a circular pleated filter media pack having circularupstream and downstream flow faces 420. A circular shape also allows fordeep pleat technology to be used in circular pleated filter packs wherea substantial amount of filter media is constrained within the volume ofthe filter media pack 418 as shown in FIG. 57. This media pack is alsoformed according to the similar methodologies as described above forexample in relation to FIGS. 47 and 48 and otherwise where discussed inthis application with trimming of the panels to the width shown in FIG.57. The description for those embodiments is also applicable to FIG. 57.It can be seen in this embodiment that each set of pleat panels arevariable and span across a lateral distance extending perpendicular tothe flow direction through flow faces 420 as variable width panels 422extend from a front side 424 to a back side 426.

As in many of the embodiments, the flow through the flow faces isgenerally transverse and typically or preferably perpendicular to theflow faces and thus is a straight through flow or direct flow throughwhich in this case in the pleated filter media pack 418 of FIG. 57 islongitudinally or along the axis that cuts through the circular flowfaces the axis being directed through the centers of the flow faces.

FIG. 59 illustrates a slanted pleated filter media pack 428 whereinslanted embossed panels 430 and slanted flat panels 432 extend atoblique angles relative to the plane of the flow faces 434. This can becreated through appropriate creases and the folding techniques at thepleat tips 436 by providing an additional angle or bend 438 asindicated.

Also as with the other embodiments, flow through the filter media packbetween flow faces 434 is from one flow face towards the other flow facewith the air flow having to pass through the filter media sheet suchthat unfiltered air flow between the flow basis 434 is not permitted.This may also be employed and used very similar to cuboid shapes butalso allows for design variation for a variety of reasons.

FIG. 58 illustrates yet another curve in this case corkscrew pleatedfilter media pack 440 that is accomplished by shifting individual pairsof embossed and flat panel pairs 442 relative to each other. Forexample, adjacent sets of pleat panels or pleat panel pairs 442 areshifted relative to each other such that at least two of the filtersides are non-planar and in this case all four sides 444 are curvedsides to form the overall corkscrew shape. Only the sides defined by thepleat panel pairs 442 are flat in this embodiment. It should be notedthat two of the sides (e.g. the sides where the scores and pleat foldsare located) form flow faces 446 with one being an inlet flow face andthe other being an outlet flow face.

Turning to FIG. 60, it is seen that there is another embodiment of apleated filter media pack 448 shown in FIG. 60 but wherein only two ofthe panels 450 are shown and also separated from one another forillustrative purposes. However it will be understood that additionalpleat panels similar to those of panels 450 would be joined at the freeends integrally via a continuous sheet and compacted together like theother embodiments.

In this embodiment, each pleat panel 450 includes embossments includinga first set of embossments 452 and second embossments 454 that togetherprovide for an overall embossment feature that extends a full lengthbetween flow face 456 and flow face 458 wherein one of the flow faces isan inlet face and the other is an outlet face. The flow faces may bedefined and provided by pleat tips 460, 462 as is the case with theother embodiments as well.

Additionally, it can be seen that the first embossments 452 differ fromthe second embossments 454 to provide for additional support, filtrationor other functional features. In this case, the first embossments 452extend from a first plane of the panel into an upstream face of thefirst panel and the second embossments 454 extend into a downstream faceof the first panel 450. In other words, the first and second embossments452, 454 project from opposite sides of the filter media sheet in thisembodiment which provides an overall thicker embossed structure to theoverall sheet. The embossments generally extend between the opposedpleat tips 460, 462 at the opposed flow faces 456, 458. This may also beused to form a cuboid and rectangular filter media pack such as thefilter media pack 16 shown for example in FIG. 1 and FIG. 43 but mayalso be used for other embodiments as well.

FIG. 61 shows a pleated filter media pack 464 much like that of FIG. 60such that it will be understood that filter media pack 464 of FIG. 61 isstructurally the same as the embodiment of FIG. 60 such that theabove-described features for that of FIG. 60 including how it isillustrated are applicable to this embodiment. However additionalfeatures and distinctions will be discussed. In this embodiment, thefirst set of embossments 466 and second set of embossments 468 thatproject from different sides of each pleat panel extend only a partiallength between opposed pleat tips or flow faces 472, 474 for example,the embossments 466, 468 on panel 470 are adjacent to the upstream pleattips and flow face 472 and spaced via a gap from the pleat tip definedby the other flow face 474.

The other pleat panel joined to pleat panel 470 at the pleat tip shownat flow face 476 (and also would be joined at pleat tips that would beat flow face 472) include first and second sets of embossments 478, 480that project from opposite sides of the plane of the filter media sheet.In the aggregate, the embossments 478, 480 in conjunction with theembossments 466, 468 provide an overall embossment structure thatextends a full length of the filter media sheet between flow faces 472and 474 to provide for bridge strength through a central region of thefilter media pack 464. Embossments 466, 468 and embossments 478, 480overlap with each other (that is they are at least adjacent to eachother or that extend past each other in the middle region sufficient toprovide for bridge strength) in the middle region.

Turning next to FIG. 62-66, optional tab features are shown that may beintegrally formed with the filter media sheet or separately attached tothe filter media sheet and usable in any of the embodiments of filtermedia packs disclosed herein. As such the afore-described features ofprior embodiments are also applicable to these embodiments. Howeveradditional features and components used in these embodiments will bedescribed and discussed that are usable with the other embodimentsdiscussed herein.

FIG. 62 shows a filter media pack structurally the same as filter mediapack 16 shown for example in FIGS. 1 and 43 but for illustrativepurposes only two of the pleat panels are shown and further, the pleatpanels are separated and pivoted away from each other for illustrativepurposes to better convey concepts to the reader.

In this embodiment, two separate tab structures are provided, althoughembodiments may include none or only one of the tabs.

One type of tab are the seal support tabs 482 that are bonded viamechanical or adhesive, pressing or other bonding attachment to flatpleat panels 472. Support tabs 482 project outwardly from opposed sideedges 80, 78 of the filter media sheet to support a housing seal 484that would extend in a continuous annular loop much like the annularrectangular housing seal shown for FIG. 36 for example. The housing seal484 is integrally bonded to both the seal support tabs 482 as well asintegrally bonded preferably to both the embossed pleat panels 70 andflat pleat panels in the finished media pack (recalling that the panelsare pivoted away and separated only for illustrative purposes in FIG.62). The seal support tabs include a first attachment portion 486 bondedto one of the pleat panels (in this case the flat pleat panel 80); and aseal support portion 488.

The seal support portion 488 may include irregularities and not beplanar to have seal bonding enhancement to prevent seal delamination.

For example, the seal support portion 488 may include holes throughwhich the seal material of the housing seal 484 flows during formation.For example the housing seal may be molded from polyurethane that flowsthrough the holes 490.

During formation of the housing seal 484 and when the seal material isyet uncured, and in a fluid state, the seal support portion 488 of theseal support tabs are embedded in the seal material of housing seal 484as well as portions of the opposed side edges 78, 80 of the sheet andacross the first and last end panels of the pack whether they be flatpanels or embossed panels to complete and form an annular surroundingperiphery of the pleated filter media pack.

It is preferred that the seal support tabs 482 are formed of a morerigid material than that of the filter media sheet 12 to provide foradditional seal support and attachment. For example the tabs maycomprise plastic, paperboard, or metal material.

While only one flat panel 72 is illustrated it will be understood thatthe various flat panels or alternating flat panels if desired and alsoif desired embossed panels 70 may also include and have the seal supporttabs 482 attached thereto. Such that a variety of seal support tabs mayextend in an array around the rectangular periphery of the media pack.

Additionally, a second type of tab is provided in the form of pleatsupport tabs 492 that include a first wing 494 and a second wing 496connected by hinge 498. It can be seen that the hinge is positioned overthe pleat tip 500 and serves to fasten and provide for additionalsupport at the pleat tip regions where the embossments merge or diminishin size as they merge into the pleat tip. The wings 494, 496 are pivotalabout the hinge 498 and are cinched and fastened together by a suitablefastener such as rivet 502 that may be pressed and snap-fitted into ahole 504 (or in alternative to snap fit, the other end of the rivetdeformed to provide an enlarged head once pressed through hole 504).

It will be understood that in a finished pleated filter media pack, thepleat tip 500 and fold will be completed such that the correspondingflat pleat panel 72 and embossed pleat panel 70 will extend parallelwith each other in the context of a filter made according to thisarrangement and as such the wings 494 and 496 will also extend parallelto each other when the rivet 502 is snap-fitted or otherwise securedwithin hole 504.

It will also be understood that the pleat tips 500 at both upstream anddownstream flow faces may be cinched together with pleat support tabs492 even though FIG. 62 shows that the pleat support tabs only at one ofthe pleat tips and flow faces provided thereby. Further, at either orboth flow faces, all of the pleat tips 500 may be fitted and cinchedwith pleat support tabs 492 or alternatively alternating or selectedpleat tips 500 may be fitted with pleat support tabs depending uponwhere additional cinching and support is desired.

Turning to FIGS. 65 and 66, the filter media package 16 is additionallyshown to include a trimmed edge that may be along one or both side edges78, 80 that defines an integral tab 506 formed into the filter mediasheet 12. Thus, the tab 506 is formed of the filter media. The integraltab 506 is another form of a seal support tab but in this case it isintegrally formed and projects outward from a remainder of the side edge78 and/or 80. By projecting outward, the integral tab can more readilybe embedded within a molded housing seal 508 during the formation ofhousing seal 508 prior to curing of the housing seal and when it isstill in a fluid state. Again the housing seal 508 would also extendaround a periphery of the completed filter media pack much like thehousing seal shown for FIG. 36 for example. Housing seal 508 may notextend in a diagonal or skew relative to the inlet and outlet flow facebut may extend in the same plane as the inlet and outlet face asillustrated in this embodiment and as such for the embodiment shown inFIG. 64.

In FIG. 67, the filter media pack may be the same filter media pack 16as shown in prior embodiments but additionally includes pressed thereina graphic and brand 510 that provides at least one of brandidentification (e.g. trademark), an indication of flow direction, andinstallation information filter media parameters, and/or part numbers.This may convey important information to the mechanic, customer or otheruser of the filter media pack 16. This may be imparted simply on one ofthe exposed end panels or may be conducted throughout the filter mediasheet. When it is done on the end panels it may be conducted by aseparate press plate that may be interchanged during manufacture withthe embossed press plate at press 28 or employed in a separate pressstation similar to press 28 positioned downstream of the press and inseries with the press shown in FIG. 1. The brand may take the form of anembossment or may also take the form of flattening of a previouslyformed embossment but this is advantageously formed via pressingoperation.

It will be appreciated that such information such as the branding andsome of the other embossment features shown herein may not readily beformed via circular rolls.

Further, press plates being planar are much less expensive thanembossing rolls and thus using press plates provides for additionaladvantages over using rolls in embodiments. Many different press platesof different shapes sizes and configurations can inexpensively be madeand interchangeably used in the various press assemblies and lineembodiments discussed herein.

In the FIG. 67 embodiment, it is shown that the brand 510 also takes theform of an embossment but again it is noted that it may simply bestamped flat and flatten the embossments previously formed rather thanbeing an embossment. Thus this provides another type of feature inaddition to embossments and score lines that may be pressed into thefilter media pack using stamping dies. The brand forms a type of graphicthat can readily be understood and convey useful information to an enduser, customer or other interested party.

FIGS. 68-79 are illustrated to show different types of embossments andthat not all embossments need to be uniform or identical and furtherthat embossments may nest within each other. Any of these embossmentstructures may be employed and formed into the stamping emboss platesand into the corresponding filter media sheets in the variousembodiments of filter media packs and embossed sheets disclosed herein.Further, these images show close-up images of the embossments to showthat the embossments may define a projection on one side of the filtermedia sheet and thereby on the other side of the filter media sheet agroove. Various patterns are shown to include saw tooth pattern, offsetpatterns, symmetrical patterns, and nesting patterns as well asdifferent heights, widths and configurations. Additionally, theembossments also may define and provide grooves between adjacentembossments.

As used herein, the term embossment is meant to be broad to generallyinclude a structure that stands out in relief. Preferably the embossmentwill include and provide for grooves as discussed herein in the case ofa filter media sheet which typically has a predetermined caliperthickness.

Turning to FIGS. 80-85, different configurations of embossments arepossible with curved embossments 512 and linear embossments formed inthe various different embodiments of pressed pleat panels shown forFIGS. 80-85. It will be understood that these embossed pleat panels ofFIGS. 80-85 are usable in any of the filter media pack embodiments andsome of them such as FIGS. 80 and 81 are particularly useful inassociation with pocket pleats to direct flow through an outlet facethat extends not only over the plate tip but also along the side edgesor seams of bonded adjacent side edges of individual pleat panels. Thus,the afore-described features of the prior embodiments are applicable tothese embodiments and additional features and distinctions will bediscussed with the understanding that these embossed panels may be usedor substituted for the embossed panels of the filter media sheetemployed in the other filter media packs.

In FIG. 80, the curved embossments 512 project from the pleat tip 516 atthe inlet flow face and includes linear embossments 514 in the middleregion. The curved embossments 512 that extend away from the linearembossments 514 as the curved embossments 512 extend from the pleat tip516 at the inlet flow face towards the outlet flow face (or vice versafrom the outlet flow face to the inlet flow face). This is particularlyadvantageous when using pocket pleats when air is permitted to flow notonly axially through the media pack but also laterally through the mediapack in the direction of the curves.

In each of these embodiments, dashed lines are used to indicate thatembossments being curved embossments 512 or linear embossments 514 canproject not only from one side of the plane of the filter media sheetbut also from the other side of the filter media sheet. Additionally oralternatively the dashed lines may also be understood in anotherembodiment to be a separate embossed sheet immediately behind the frontembossed sheet in which the curved embossments of the two sheets nestwith each other (project in gap regions between embossments) and thelinear embossments nest with each other which can be the case as wasshown for example in FIG. 79.

Turning to FIG. 86, an alternative embodiment of a machine assembly line520 is illustrated. It will be understood that the machine assembly line520 is structurally the same as the machine assembly line 10 of thefirst embodiment shown in FIG. 1 such that the afore-described featuresof the prior embodiments discussed in association of FIG. 1 are alsoapplicable to this embodiment including the optional features used forthat embodiment. It will also be understood that this machine assemblyline 520 may be used to form the various embodiments of pleated filtermedia packs of the various filter media packs described herein and isusable for that purpose. As such, additional features and distinctionswill be discussed and it is also understood that in this embodimentmultiple presses are provided that may be used to provide for differenttypes of embossments including two different types of embossed panels ifdesired.

In this embodiment the filter media roll 14 and its filter media sheet12 along with optional laminate sheet 88 coming from optional laminateroll 90 are driven in a travel pack 522 from an upstream region to aplate collector in the form of pleater 524 which is schematicallyillustrated. In this machine assembly line 520 the filter media sheet 12may be continuously driven along the travel path by advance rolls 526and not stop intermittently or stop at all during processing, that isuntil filter roll 14 is exhausted and stoppage is necessitated forchange-out or break-down. This is accomplished by an endless loop 528 ofa plurality of presses 530 that are rotated along the endless path ofthe loop 528. The presses 530 may be similar to the press 28 asdescribed in conjunction with FIG. 1 including all of its componentsincluding the ram, upper stamping die, lower stamping die and controlsbut in this instance the presses 530 are driven in the endless loop inthe direction indicated in FIG. 86 and at the same speed as the filtermedia sheet along the travel path such that intermittent stoppage is notnecessary. However this may also be used with intermittent stoppage ifdesired to allow for dwell time and may alternatively provide for theadvantages of pressing different types of embossments into differentpanels as may be desired.

It is noted that part of the loop 528 that extends over the travel path522 when the presses 530 are engaged in actively pressing the media islinear and travels parallel and at the same speed as travel path 522.Further, while the presses 530 are disengaged in traveling around thecurvature of the loop, they may be disengaged and heated. Inactivepresses along the loop may also have plates switched out to providebranding or other lengths of embossments or other features.

Additionally, the media advance conveying mechanism in this embodimentmay be the presses itself and it may not be necessary to have theadvance rolls 526 in that the presses and being driven in the endlessloop and in engagement with the filter media sheet itself can drive andconvey the filter media sheet along the travel path.

Optionally, adhesive applicators to apply adhesive such as hot melt maybe used and further, a trim knife such as a water jet, laser, shearknife or cross-cut knife or other such knife may be used to cut andshape and slit the media as may be desired. This may be done on acontinuous basis.

Optionally, the tooling plates of the presses 422 are heated and havemultiple heat zones and may be also heated while disengaged from thefilter media sheet.

Turning to FIG. 87, yet a further embodiment of a continuous process diepress pleater and machine assembly line 540 is illustrated where it isunderstood that it is structurally the same and includes presses and itscorresponding features as in the first embodiment shown in FIG. 1 andalso able to form the various filter media packs of the variousembodiments disclosed herein. However additional features anddistinctions will be discussed with reference to this embodiment. Inthis embodiment the machine assembly line 540 includes a table havinglinear slides 544 that facilitate linear reciprocating movement of twoindexable pleat press carriages 546, 548 (each of which may include oneor more pleat presses if desired in series).

The filter media roll 14 and its filter media sheet are driven along atravel path 552 that is linear and extends toward a pleat collector inform of pleater 550 that is schematically indicated at the downstreamend with the pleat press carriages 546 and 548 therebetween. It will beunderstood that each pleat press carriage incorporates and carries apress that is similar to press 28 as described in the first embodimentto include the upper and lower stamping dies and the electronicallycontrolled ram. However in this embodiment, the pleat press carriagesreciprocate along a linear path on the linear slides forward andbackward parallel to the travel path 552. In this instance, pleat presscarriage and its press are actively engaging and pressing the filtermedia and thereby engaged with the filter media sheet as it is beingtravelled along the travel path. The pleat press carriage 546 is movedat the same speed as the filter media sheet 12 along the travel path552. Additionally, it will be understood that pleat press carriage 546may not just include one set of emboss and score plates but perhaps aseries of several presses and corresponding upper and lower embossplates along the line to press several pleat panel sections at the sametime or in sequence.

While the press carriage 546 is engaged and actively pressing andadvancing the media, the pleat press carriage 548 is disengaged andtraveling in a reverse direction to be at a point where it can startpressing panels immediately behind the engaged pleat press carriage 546that is traveling forward with the media sheet. Once the pleat presscarriage 546 completes its pressing, it will disengage and also thentravel backwards while at the same time or about the same time the pleatpress carriage 548 that is disengaged will become engaged and start topress and then move along the travel path 552, at the same speed as theadvancement of filter media sheet 12. In this embodiment, the presscarriages themselves when engaged may drive the filter media sheet alongthe endless path and may do so in a continuous non-intermittent fashionthereby increasing production in capacity. This also may be outfittedwith the various optional features of the prior embodiments discussedthe machine assembly lines 10 or 520.

Yet a further embodiment of a machine assembly line 560 is illustratedin FIG. 88 which is structurally the same as the embodiment shown inFIG. 1 and may include also the features desired in FIG. 1 such that theafore-described features of the embodiments associated with FIG. 1 areapplicable to this embodiment. Further, this machine assembly line 560is also usable in producing the filter media packs according to thevarious embodiments discussed herein.

In this embodiment the filter media sheet 12 coming off filter mediaroll is pressed by a different form of press having lobed nip pressesthat are driven vertically into and out of engagement via a ram providedby hydraulic or electrical linear actuators 564. The lobe nip pressesinclude stamping dies that have at least one planar section 566 and thusare an emboss plate, and may have rounded edges or lobed sections 568the lobed nip rollers may be driven by the linear actuators 564 to notonly facilitate linear pressing but additionally, rotary actuators 570may rotate the lobe nip presses 562 when not in a dwell press mode toadvance the media and score the media in the radius lobed sections 568that can define scoring features along the lobes. It is noted that ineach stamping die the planar section may be embossed both above andbelow such that as it rotates the other press emboss plate is used onthe other side of the stamping die.

FIG. 89 illustrates a progressive stamping die arrangement 574 that maybe used in any of the presses of the embodiments described herein suchas used in machine line assemblies 10, 520, 540, and 560 for example. Assuch it will be understood that the description and disclosurepertaining to those embodiments are also applicable to the progressivestamping die arrangement 574 of this additional embodiment such thatdistinctions and additional features will be discussed.

In the progressive stamping die arrangement 574, the embossment features576 are spread out among a plurality of progressive stamping dies 578that extend transverse to the flow path of the filter media sheet alongits travel path (see e.g. side edges 78, 80 of the filter media sheet12). It is noted that in some embodiments, especially where theembossments are deep that stretching of the filter media sheet and thefibers may be realized to provide for increased air flow permeabilityhowever, if stretching is not desired and deep embossments are at thesame time desired then the progressive stamping die may be used as ittends to gather and move in the filter media sheet progressively ratherthan stretching and may also be used to compress instead in anembodiment. Specifically, a first set of central stamping dies 580 arefirst driven into engagement which gather the filter media sheet andmove outer portions 582 inward thus moving the opposed side edges 78, 80inward slightly as the embossments and the corresponding groove featuresare being formed into the filter media sheet. After the central stampingdie 580 is engaged the next outside guard stamping dies 584 are engagedwhich tend to draw and pull the outer portions 582 and the correspondingside edges 78, 80 inward even further again with little or no stretchingand then the outermost stamping dies 586 are subsequently engaged tofinish off formation of the embossments in the filter media sheet.

With the sequential engagement of the progressive stamping dies from thecentral stamping die outward to the guard stamping dies 584 then theoutermost stamping dies 586 a progressive stamping of the filter mediasheet is accomplished that does not necessarily have to stretch thefilter media sheet and that may also be used to compress the filtermedia sheet if desired to reduce air flow permeability and/or increaseefficiency of the filter media sheet.

Turning to FIGS. 97 and 98, an additional embodiment or features for thepleated filter media packs 16 are illustrated that may be optionallyused with the filter media pack 16. Specifically, these featuresdiscussed below may be used in the filter media packs of any of theembodiments of filter media packs discussed herein and may beaccomplished by welding (such as via ultrasonic welding or other meltingof media together) and/or by way of dispensing adhesive beads and/orpressing. In particular, these features may be accomplished by way ofthe plunge welder 84 and anvil 86 discussed in association with FIG. 1,other welding apparatus or by way of the adhesive applicator 82 whichmay dispense adhesive dots, lines at select locations on the filtermedia sheet.

As shown the filter media pack 16 is shown to include point bonds 100which may be at the pleat tips as shown in FIG. 97 as well as atintermittent locations between pleat tips as shown additionally in FIG.98. Again these may be ultrasonic welds or alternative placement ofadhesive bead dots that may optionally be pressed together. Thisprovides for additional structural integrity and at the pleat tips maycinch the pleats together to provide a wider mouth to allow foradditional air flow through the flow face defined by the pleat tips suchas shown in FIG. 97.

Additionally, this embodiment shows that embossed pleat panel 70 may beseamed to adjacent flat pleat panels 72 in pairs to form pocket pleats604 with three pocket pleats being illustrated in the embodiment of FIG.97. In this embodiment in addition to being able to flow through theflow face defined by pleat scores 68, and thus flow in a direct manner,the air flow may additionally flow sideways or laterally out between theopen regions 606 defined between adjacent pocket pleats 604. The seams602 may also be formed either through adhesive application by formingand laying a continuous bead and then pressing the adjacent pleat panelstogether when forming the pocket pleats and pleating or byultrasonically welding. It is also understood that while only one sideis shown in FIG. 97 for side edge 78 that it is also applicable and thatthe same seam 602 would also be formed on the other side or side edge 80(not shown in FIG. 97 but understood from other figures).

It is additionally noted that the point bonds 600 will also prevent andlimit relative movement between adjacent pleat panels to provide forstructural support and prevent collapsing or blinding off of the filtermedia sheet when subjected to an application where substantial air flowis run through from the inlet face to the outlet face.

While not being limited thereto, certain examples and performance aredescribed below. While the press can be used to process a variety ofconventional filter medias that may include polymers, glass and/orcellulose as described above and thereby provide corresponding mediapacks with embossments and each can have advantages over conventionalpleat packs, certain performance advantages can be obtained by use ofmedias that include polymer materials with the press. For examples,polypropylene media grade A2 and polyester media grade LFP 2.0 have beenfound to have sufficient to excellent processability with the press ofFIGS. 2-13. The selected medias were chosen based on how well they wereprocessed and how well they performs in system level lab tests. Thesemedias may be commercially available melt blown medias from IREMA-FilterGmbH and sold under the IREMA brand, having an business address at Ander Heide 16, D-92353 Postbauer-Pavelsbach, Germany. The characteristicsof these medias are as follows in the TABLE 1 below, but it iscontemplated that similar medias or variations of these grades willperform similarly. Additional high performance medias include Irema LFP2.3 (polyester), Irema LFP10 (Polyester) available from Irema as notedabove, and Grade 30XzPN/DG7513 (Glass/Polypropylene) which is availablefrom Transweb, LLC of Vineland, N.J. that may be useable in embodiments.

TABLE 1 flat and embossed sheet parameters Irema A2 Irema LFP 2.0Material Polypropylene Polyester Mold/Press Temperature (of 240 335press plates in FIGS. 2-13 in degrees Fahrenheit) Press Time 5 seconds 5seconds Flat Sheet Basis Weight 202 211 (gsm) Embossed Basis Weight 171210 (gsm) Stiffness Flat (mgs) 264.1 197.38 Stiffness Embossed (mgs)954.6 654.9 Mean Flow Pore (μ) 13.7 10.6 Largest Detected Pore (μ) 41.831.4 Mean Flow Pore - 13.2 14.0 Embossed(μ) Largest Detected Pore - 52.843.6 Embossed(μ) Permeability Flat (cfm) 58.26 36.5 PermeabilityEmbossed 140.20 96.43 (cfm) Embossment Height 85% 93% RetentionEfficiency Flat 0.3-1.0 μ % 98.66 92.30 1.0-3.0 μ % 99.69 96.24 3.0-10.0μ % 99.98 99.51 Efficiency Embossed 0.3-1.0 μ % 95.00 68.93 1.0-3.0 μ %97.53 76.29 3.0-10.0 μ % 99.22 92.83 Dust Holding Capacity Flat 0.8650.8145 (g/100 cm² @ 1000 Pa) Dust Holding Capacity 1.637 1.824 Embossed(g/100 cm2 @ 1000 Pa)

Using these medias and embossing as described above using the embodimentof FIGS. 2-13 and as described in Table 1 (with the plates having anemboss groove depth of 0.18 inch and an emboss groove width of about 0.3inch for the A2 example, and an emboss groove depth of 0.125 inch and anemboss groove width of 0.165 inch for the LFP2.0 example), standardcuboid shaped pleated filter media packs (e.g. shaped like as shown inFIG. 43, or FIGS. 36, 37 or FIG. 1) were created having a height of 7.5inches, a width of 7.5 inches, and a length of 8.2 inches (volume of 461cubic inches). These media packs were compared to a commerciallyavailable Donaldson® Brand G2 fluted filter media pack having a heightof 7.9 inches, a width of 7.5 inches, and a length of 8.2 inches (volumeof 487 cubic inches and designated as comparative “C1” example in Table2 below). The following performance characteristics of these examplesare detailed in Table 2 below.

TABLE 2 Cuboid Filter Media Pack Performance C1 A2 LFP10 LFP2.0 FilterMedia Sheet Area (inch²) 12053 5299 5299 5332 Challenge Flow Rate (SCFM)500 500 500 500 Initial Pressure Drop (PSID) 5.4 5.5 5.2 5.75 InitialEfficiency (%) 99.63 99.9 99.05 99.6 Accumulative Efficiency (%) 99.9799.96 99.87 99.95 Dust Holding Capacity (g) 1528 1359 1128 1583 Grams ofdust/inch² of media .13 .26 .21 .30 Volumetric Dust Holding 3.1 2.9 2.43.4 Capacity (g/inch³)

A substantial performance advantage above can be seen in thatsubstantially less filtration media sheet in terms of area isnecessitated while achieving a similar efficiency, restriction and dustholding capacity and performance. As such, substantially less filtermedia sheet may be required in some embodiments to achieve similarresults and greater dust holding per square inch of media sheet wasobtained. For example, the above demonstrates that filter media packscan be formed having an initial efficiency of at least 99%, and a dustholding capability of at least 0.15 grams of dust/inch² of media, moretypically at least 0.2 grams of dust/inch² of media and in someembodiments at least 0.25 grams of dust/inch² of media.

For the flat and embossed sheets tests above as in Table 1 (and for anypatent claims appended hereto that recite an efficiency and/or dustholding capacity for sheet performance), the testing was and can beconducted with a Palas MFP 3000 test stand with the following conditionsin Table 3:

TABLE 3 filter area: 100.000 cm² face velocity: 5.8 cm/s dust massconcentration: 150.0 mg/m³ dust/aerosol: SAE fine A2 total volume flow:35.0 l/min Dust load termination at 1000 Pa increase.

For the filter pack volumetric performance testing such as the cuboidfilter media pack performance and tests for Table 2 above (and for anypatent claims appended hereto that recite an efficiency and/or dustholding capacity for pack performance), the testing is pursuant to ISO5011:2014 (i.e. the ISO test standard for Inlet air cleaning equipmentfor internal combustion engines and compressors—Performance testing),utilizing ISO fine test dust, at an air flow of 500 CFM, and dustload/test termination at a pressure drop or restriction of 30 inches ofwater.

Additionally, while the above embodiments are described as useful withadvantages for pleated filter media packs, it will be understood thatthe press and methods disclosed herein may be used with other types ofmedia packs beside pleated such stacked fluted media panels as thosedescribed in the background section (e.g. such as in U.S. Pub. No.2014/0260139 entitled Rectangular Stacked Fluted Filter Cartridge toMerritt) and as such certain broader claims (for example claims that donot explicitly require pleats or pleated) that are appended hereto aremeant to encompass such possibilities.

Additionally, another embodiment of filter 700 is illustrated in FIG. 99in the form of an irregular shape to define a brand that provides atleast one of brand identification, flow direction, installationinformation, filter media parameters, and part number. The filter 700comprises a filter media pack 702 with an inlet face 704 and an outletface generally indicate in the area of 706 (although the flow faces maybe reversed with the inlet the outlet and the outlet the inlet as inother embodiments). The filter media pack is also preferably of theirregular shape to define a brand that provides at least one of brandidentification, flow direction, installation information, filter mediaparameters, and part number.

Preferably, the filter 700 further comprises a frame 708 over the filtermedia pack 702 and supporting the filter media pack 720, the frameincluding alphanumeric letter characters to form said brand, which inthis case spells the brand name CLARCOR as seen in FIG. 99.

The frame 708 may take the form of and thereby include a grate 707forming the alphanumeric letter characters, with the grate 707 over oneof the inlet face 704 or outlet face 706 of the filter media pack.

Preferably, the frame 708 also includes a surrounding sidewall 703projecting from the grate 707 toward the outlet face or inlet face insurrounding relation of the filter media pack.

Typically, the filter media pack will comprise a plurality of filtermedia panels 711 having a depth projecting between the inlet face andthe outlet face. The filter media panels 711 also have a width extendingbetween opposed sides (see sides 710) of the filter. As can bet seen,the filter width between opposed sides 710 is variable and not constant.Further, the filter media panels 711 are in an array (one panel disposedover the next panel in a linear array in this instance) between opposedends 712 of the filter. It is seen that the opposed sides 710 extendtransversely and preferably perpendicularly between ends 712. Toaccommodate the shape variance of the branding, the filter media panels711 have different widths between opposed sides to form at least part ofa shape of the brand.

Additionally, it also may be that as shown that the adjacent the firstand second ends 712, the filter media panels 711 are of different widthssuch that a span of the filter between opposed ends 712 varies as theends 712 project from a first of the opposed sides 710 to a second ofthe opposed sides 710.

As is the case in earlier embodiments, the filter media panels 711 arepleated and form a pleated filter media pack with trimmed edges form thedifferent widths between opposed sides, such as via use of the trimmingtools shown in FIG. 1 or FIG. 86.

Another aspect of this embodiment is that a filter frame providing brandidentification. The frame 708 may be in the form of and may thereforeinclude grate 707 disposed over the filter media pack having voids 715to allow airflow and members 716 around the voids and in the form of atleast one alphanumeric character to provide a brand that provides atleast one of brand identification, flow direction, installationinformation, filter media parameters, and part number.

As per above, the span of the filter media pack is preferably variableand helps form the shape of at least one alphanumeric character.

Also preferably, a plurality of alphanumeric characters are provided(e.g. to spell CLARCOR) and a span of the filter media pack is trimmedto help form the shape of at least 2 of the alphanumeric characters.

Finally, while not shown, it is contemplated that a gasket or sealprojecting from the outline of the frame at the inlet or outlet face maybe provide and extend in cantilever fashion to form a radial or axialseal, or alternative a seal may be provide in surrounding relation ofsidewall 703 and supported thereby to provide for an axial pinch gasketor a radial seal.

Returning with reference to Table 1, it is noted that the embossedpanels of the sheet are much stiffer than the flat or unembossed panelsof the sheet as the “Stiffness Flat” and “Stiffness Embossed” areprovided for different sections of the sheet. It is noted thesestiffness measurements herein are measured using standard “bendingresistance of paper (Gurley-type tester)” protocols and standardsestablished under TAPPI 2011 published standard T 543 om-11. A length of63.5 mm (2.5 inches) and width of 50.8 (2 inches) was used (e.g. cuttingportions from the respective different pressed sections and differentpanels for testing) and therefore should be used. Using a standardGurley-type tester (in this instance a Gurley Bending Resistance Tester,specifically Model 4171E, made by Gurley Precision Instruments of Troy,N.Y.), a stiffness reading was thereby generated and reported in Table1, which provides for reading comparison of relative stiffness.

From Table 1, it can be observed that one panel can be configured to bemuch stiffer than the other panel in a pleated sheet configuration toprovide different sections of the pleated sheet with different strengthcharacteristics. More specifically, the embossed sheet can providebridge strength and maintain the integrity of the pleated filter packand thereby better prevent collapsing or reduce distortion or blindingoff of media during operation thereby maintaining high capacity forfiltration and dust removal while reducing pressure drop.

Accordingly, preferably, one panel (such as a portion of the embossedpanel) includes a first stiffness that is at least 2 times as great,more preferably at least 3 times as great as another panel (such as aportion of the flat or otherwise unembossed panel adjacent the embossedpanel in a pleated sheet configuration embodiment).

By controlling the depth of the embossments, greater or lesser stiffnessvariance between different portions provided by different panels can berealized. For example, deeper embossments than those used for the mediasin Table 1 will provide even greater stiffness and thereby bridgestrength, while shallower embossments than those used for the medias inTable 1 will provide less strength. While the upper limit may not becritical, generally for the range of embossment depths, the stiffness ofthe first panel (e.g. the embossed panel or a portion thereof) will bebetween 1.5 and 10 times the stiffness of the second panel (e.g. theunembossed or flat panel, or a portion thereof). In some instances allpanels may be embossed, but the embossing panels may be different fromone panel to the next, and/or one panel may be more deeply embossed ordifferently embossed or patterned than the other that may be realized bythe press techniques herein.

Further, preferably the first pleat panels are entirely embossed overthe entire panel (e.g. covering at least 90%), wherein the second pleatpanels may either be only partially embossed, or flat or not embossed atall). This provides notably different strength characteristics amongadjacent panels while different filtration characteristics also may beprovided in different panels.

Accordingly, any of the embodiments may include a feature wherebymultiple pressed sections include a first pressed section with a firstportion with a first stiffness that is at least 2 times as great as asecond stiffness of a second portion of a different second pressedsection.

Any of the embodiments that have a pleated sheet arrangement with pleatpanels may therefore include pleat panels including first pleat panelsand second pleat panels, the first pleat panels including a firstportion having a first stiffness that is at least 2 times as great as asecond stiffness of a second portion of the second pleat panels.

Optionally, in such embodiments with different stiffness regions amongdifferent portions, the first portion is embossed and the second portionis unembossed.

Further, in embodiments, the first pleat panels may entirely beembossed, and wherein the second portion of second pleat panels may beentirely unembossed.

Most preferably, in many of the embodiments, the first stiffness is atleast 3 times as great as the second stiffness.

All references, including publications, patent applications, and patentscited herein are hereby incorporated by reference to the same extent asif each reference were individually and specifically indicated to beincorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

What is claimed is:
 1. A method of forming a filter media pack with afilter media sheet, comprising: pressing embossments into the filtermedia sheet repeatedly with stamping dies, the stamping dies being in anon-roll form, wherein the stamping dies comprises a first die and asecond die that together include a pair of plates movable toward andaway from each other, the plates including mating female and maleembossment features that form the embossments; creasing the filter mediasheet at spaced intervals to form a plurality of pleat panels withadjacent pleat panels integrally joined together through creases formedby creasing, at least some of the pleat panels including theembossments; and assembling multiple pleat panels of the filter mediasheet into the filter media pack to include pleats having an inlet sideand an outlet side that are separated by a span of greater than 6centimeters.
 2. The method of claim 1, wherein the stamping dies aresuccessively pressed and released, during the pressing the stamping diesengaging for a dwell time and then released.
 3. The method of claim 1,wherein said assembling comprises gathering the multiple pleat panels bymoving the pleat panels into overlaying relationship.
 4. The method ofclaim 3, wherein the creases provide a plurality of pleat tips, thefilter media sheet being a continuous sheet extending through the pleattips that is gathered subsequent to said creasing to form a pleatedfilter media pack.
 5. The method of claim 4, further comprisingconducting the creasing by said stamping dies with crease extensionssecured to the plates wherein the creasing is conducted simultaneouslywith the pressing embossments, and the crease extensions comprising amale score extension interacting with a female score extension andforming the creasing.
 6. The method of claim 5, further comprisingadvancing the filter media sheet along a travel path, extending thecreasing in a direction that is perpendicular to the travel path andextending the embossments between adjacent creases.
 7. The method ofclaim 1, further comprising advancing the filter media sheet along atravel path, extending the creasing in a direction that is perpendicularto the travel path and pressing said embossments into a first pleatpanel of the filter media sheet and skipping the pressing by the pair ofplates on a second pleat panel that is connected to the first panel bythe creasing by advancing the filter media while the pair of plates areseparated, such that the first and second pleat panels mismatch, andsuccessively repeating to create a plurality of first and second pleatpanels that mismatch.
 8. The method of claim 1, further comprising:intermittently and successively advancing and stopping the filter mediasheet along a travel path, wherein while the filter media sheet isstopped said pressing is conducted and wherein while the filter mediasheet is advancing the filter media sheet passes freely through thestamping dies.
 9. The method of claim 8, during said stoppingadditionally conducting at least one of the following operationsdownstream of the pressing dies: (a) bonding of adjacent pleats formedby a pleating operation; (b) trimming edges of adjacent pleats, theedges extending in the direction of the travel path; (c) cinching pleattips at least one of an inlet face and an outlet face of the filtermedia pack to increase air flow entrances or exits at the at least oneof the inlet face and outlet face; and (d) structurally couplingcomponents to adjacent panels formed by said pleating.
 10. The method ofclaim 1, further comprising linearly reciprocating the pair of platestoward and away from each other during said pressing with the matingfemale and male embossment features received into each other with thefilter media sheet therebetween.
 11. The method of claim 1, furthercomprising heating the filter media sheet for the pressing to atemperature below a glass transition point of fibers of the media suchthat fibers are not bonded together due to said heating the media, andwherein the fibers comprise polymeric fibers comprising at least one ofpolypropylene, polyester and nylon fibers.
 12. The method of claim 1,wherein said heating comprises elevating the temperature of the filtermedia sheet to between: 65 and 125 degrees Celsius for medias thatcomprise at least 50% cellulose fibers by weight; 65 and 205 degreesCelsius for medias that comprise at least 50% synthetic fibers by weightincluding at least one of polypropylene, polyester and nylon fibers. 13.The method of claim 1, said pressing forms embossments with a length ofgreater than 5 centimeters, and width of at least 2 millimeters and adepth of a least 2 millimeter.
 14. The method of claim 4, wherein saidpressing forms embossments having a depth of between 2 millimeters and 8millimeter, wherein the filter media pack comprises the pressed regionof the filter media sheet with the remainder comprising a un-pressedregion that is free of the pressing, the pressed region comprisingbetween 20% and 80% of the filter media pack.
 15. The method of claim14, wherein the filter media sheet comprises an un-pressed air flowpermeability prior to pressing and the pressed region of the filtermedia sheet comprises a pressed air flow permeability, wherein due tostretching the pressed air flow permeability being at least 110% greaterthan the un-pressed air flow permeability measured by TAPPI T251 airflow permeability test.
 16. The method of claim 1, wherein the filtermedia sheet prior to pressing has an air flow permeability of between 2and 400 CFM (measured by ASTM D737-04(2012) standard); and an initialgravimetric efficiency of between 50% and 100% for ISO 12103-1, A2 FineTest Dust measured by ISO 5011 standard, and a caliper thickness ofbetween 0.2 and 7 millimeters.
 17. The method of claim 1, furthercomprising: advancing the filter media sheet along a travel directionand further comprising pressing pleat creases into the filter mediasheet upstream and downstream from the embossments at upstream anddownstream creases that extend transversely relative to the traveldirection, the embossments including grooves that extend betweenupstream and downstream pleat creases, wherein the filter media sheetdefines a thickness between a bottom surface and a top surface, thegrooves extending into the top and bottom surfaces to define peaks andvalley defining a height greater than a thickness of the filter mediasheet, the pleat creases at an upstream end being located at a differentelevation location than the pleat creases at a downstream end, whereinthe pressing is conducted by a reciprocating ram that reciprocates apair of plate assemblies relative to each other into and out of matingengagement with the filter media sheet pressed therebetween, each plateassembly comprising an emboss plate defining the plurality of male orfemale embossment features that mate with male or female embossmentfeatures of the other plate assembly to press the grooves into thefilter media sheet, each plate assembly further including upstream anddownstream score bars adjustably mounted to opposed upstream anddownstream ends of the emboss plate, the score bars being adjustable toadjust the location of the pleat creases relative to the height of thegrooves.
 18. A method of forming a pleated filter media pack with afilter media sheet, comprising: pressing embossments into the filtermedia sheet repeatedly with stamping dies, the stamping dies being in anon-roll form, wherein the stamping dies comprises a first die and asecond die that together include a pair of plates movable toward andaway from each other; creasing the filter media sheet at spacedintervals to form a plurality of pleat panels with adjacent pleat panelsintegrally joined together through creases formed by creasing, at leastsome of the pleat panels including embossments; and gathering thecreased filter media sheet to provide the pleated filter media pack; andwherein said pleating creates pleats having a pleat depth of greaterthan 6 centimeters, and said pressing forms embossments with a length ofgreater than 5 centimeters, and width of at least 2 millimeters and adepth of a least 2 millimeter.
 19. The method of claim 18, wherein thepleats having a pleat depth of at least 15 centimeters.
 20. The methodof claim 18, wherein the stamping dies are an assembly comprising acooperating pair of emboss plates and a first pair of cooperating scorebars, wherein the pair of cooperating score bars are on a first end ofthe cooperating pair of emboss plates.
 21. The method of claim 20,further comprising a second pair of score bars on a second end of thecooperating pair of emboss plates.
 22. The method of claim 1, wherein aset of the embossments are pressed into the filter media sheet upstreamof a crease of the creases formed by the creasing.
 23. The method ofclaim 22, wherein said crease is simultaneously formed with the set ofembossments.
 24. The method of claim 1, wherein the filter media sheetprior to pressing has an air flow permeability of between 10 and 150 CFM(measured by ASTM D737-04(2012) standard); and an initial gravimetricefficiency of between 50% and 100% for ISO 12103-1, A2 Fine Test Dust(measured by ISO 5011 standard), and a caliper thickness of between 0.2and 1 millimeters.
 25. The method of claim 1, wherein a set ofembossments are pressed simultaneously into the filter media sheetbetween upstream and downstream creases, with the upstream anddownstream creases.
 26. The method of claim 25, wherein the upstream anddownstream creases are formed simultaneously with the set ofembossments.
 27. The method of claim 1, further comprising configuringthe embossments in the filter media sheet to provide the filter mediapack with an initial filtration efficiency of at least 99% and a dustholding capability of at least 0.15 grams of dust/inch² of media. 28.The method of claim 18, further comprising configuring the embossmentsin the filter media sheet to provide the pleated filter media pack withan initial filtration efficiency of at least 99% and a dust holdingcapability of at least 0.15 grams of dust/inch² of media.
 29. The methodof claim 18, wherein the pleated filter media sheet includes pleatedpanels including first pleat panels and second pleat panels, the firstpleat panels including a first portion with the embossments having afirst stiffness that is at least 2 times as great as a second stiffnessof a second portion of the second pleat panels.
 30. The method of claim7 wherein the second pleat panels are flat panels that are free ofembossments.
 31. The method of claim 18, wherein a set of theembossments are pressed into the filter media sheet upstream of a creaseof the creases formed by the creasing.
 32. The method of claim 31,wherein said crease is simultaneously formed with the set ofembossments.
 33. The method of claim 18, wherein a set of embossmentsare pressed simultaneously into the filter media sheet between upstreamand downstream creases, with the upstream and downstream creases. 34.The method of claim 33, wherein the upstream and downstream creases areformed simultaneously with the set of embossments.